TECHNICAL THEATRE PRODUCTS
Modular Theatre Flats
Features and Functions
DOOR FLAT OPTIONS
Doors can be hinged to open right or left, and can open outwards or inwards with a soft or hard close. Up to two doors can be installed in the same frame, one opening outwards, the other inwards.
EASILY MOVEABLE
Flats can be easily moved using our wheel kits. Each wheel kit is rated to move 900 pounds. We recommend a maximum of three flats be moved on one wheel kit.
EASY FLAT CONNECTION
Flats are connected using supplied steel bolts in pre-cut holes in the frame. The only tools needed are any combination of two of the following: C wrenches, socket wrenches, and an impact driver. Theatres will have access to short videos that spell out assembly instructions.
POWDER COATING
Every aluminum component is powder coated to ensure maximum damage protection and longevity of each flat. All frames, wheel kits, and support legs will be powder coated in black. Flat faces can be vinyl wrapped, or shipped plain for painting by theatre staff.
FACE REPLACEMENT
The face of every flat can easily be removed and replaced in seconds. Flats are connected to frames using panel hangers and anchor locks. To replace the face, all that is required is to lift the front panel off the frame using pre-installed handles on the rear of the flat, and install a replacement face using the same method in reverse.
TRIM ATTACHMENT & REMOVAL
Magnets are embedded into the face of the flat, allowing all trim attachments to adhere to its surface. Accordingly, the trim can be removed and changed in seconds.
FLATS CAN BE FLOWN
All flats can be flown using reinforced eye bolts on the top of the flats. At the present time, we recommend only flying flats connected together on a single level. An XL version of the flats is in development that will allow for flying multiple vertically connected flats.
EFFORTLESS CHANGING OF WINDOWS AND DOORS
The window and door trims are magnetic and removable in seconds. The window frame is secured with 8 set screws, which can be quickly replaced. The door frame uses 6, 3/8” bolts; remove them to install a new door or frame with the same bolts.
FLAT WHEEL KITS
Wheel kits are used to easily move flats. Each kit has two casters, and all it takes to employ their use is to align the flats with the wheel kit, thread a bolt, and step on a pedal to raise and move the flat. Once in place, the pedal is flipped up to lower the flat to stage floor height.
Efficient Storage & Flexible Setup
Our flats are designed for easy storage and versatile configurations. When stored vertically, ten flats occupy just a 10×4-foot space, and they can also be conveniently stored on the supplied wheel kits for easy transport.
For flexible staging, each kit includes corner pieces—two 90-degree and two 120-degree angles—with matching trim to connect flats at various angles. Custom angles are available to meet specific needs. To ensure stability, leg supports bolt securely to the frame, with base plates that can be anchored using stage weights, sandbags, or screws for solid support on any stage.
PRODUCT SPECIFICATIONS
CONSTRUCTION MATERIALS
All frames are constructed using ¼” X 2” angled aluminum and the face consists of 1/8th thick aluminum sheet. The entire manufacturing process is automated, and machine driven. All trim is EX-CEL PVC foam that can be shipped plain or customized using a hydro dipping for print, color, and texture.
DIMENSIONS AND WEIGHT
Each flat measures 4 x 8 feet. There are three basic flat designs – plain, door and window. Their weights are 93 lbs plain flat, 111 lbs door flat and 109 lbs window flat, respectively.
Product Components in a Standard Flat Shipment
This configuration represents the number of flats and accessories required to produce an average show on a 20 to 30 feet stage. Each component below is included in our starter kit, or can be purchased individually as needed.
- 6 – plain flats including trim.
- 2 – window flats including trim.
- 2 door flats including two 241/4” hollow core doors and trim.
- 2 – wheel kits
- 14 – panel support legs
- 2 – 90 degree and 2, 120-degree corner pieces.
- Steel screws for assembly and eye bolts for flying.
- All frames, support legs and wheel kits are powder coated.