Stage Weapons Safety: Firearms, Edged Weapons, and Blank Ammunition in Theater
On October 21, 2021, director of photography Halyna Hutchins was killed on the set of the film “Rust” when a firearm discharged while being handled by the lead actor. This tragedy was not unique in entertainment history: Brandon Lee was killed in 1993 when a bullet fragment left in a gun barrel was propelled by a blank cartridge, and Jon-Erik Hexum died in 1984 when he pressed a revolver to his temple and fired a blank cartridge, not understanding that the gas discharge from a blank at point-blank range is lethal. These incidents share a common cause: inadequate professional management of weapons on set. Every theater technician must understand the standards that exist to prevent these tragedies.
The Most Important Principle in Stage Weapons Safety
There are no prop guns. There are only real guns used as props. Every firearm, regardless of whether it has been modified to fire only blank ammunition, regardless of whether it has been verified to be unloaded, and regardless of how long it has been in a props cabinet, is a real weapon capable of causing death. The four rules of firearms safety apply on every stage and set without exception:
- Treat every firearm as if it is loaded, always.
- Never point a firearm at anything you are not willing to destroy.
- Keep your finger off the trigger until you are ready to fire.
- Know your target and what is beyond it.
These rules, when followed, prevent every firearms incident. Every documented entertainment firearms tragedy can be traced to the violation of at least one of these rules.
The Role of the Armorer
In any professional production that uses real firearms, a trained armorer is required. The armorer is the sole custodian of all firearms on the production. The armorer’s responsibilities include:
- Receiving, storing, and maintaining all firearms.
- Loading and unloading firearms. Only the armorer or their specifically authorized designee may load a firearm.
- Personally handing the firearm to the actor or performer immediately before the scene in which it is used.
- Personally receiving the firearm from the actor or performer immediately after the scene.
- Conducting a safety inspection of every firearm before each use, including visual inspection of the barrel for obstructions.
- Conducting safety briefings for all cast and crew who will be on set when a firearm is in use.
- Maintaining written records of all ammunition, its count, and its use.
The tragedy on the set of “Rust” occurred in part because proper armorer protocols were not followed, and the weapon was handled by multiple unauthorized persons outside of supervised use. This is the direct cause of the incident.
Blank Ammunition
Blank cartridges contain a powder charge but no projectile. However, blank cartridges are not safe to fire at a person at close range. The gas and debris discharged from a blank cartridge exit the barrel at high velocity and can cause lethal injuries at close range. The minimum safe distance for blank fire varies by caliber and charge but is generally cited as a minimum of 6 to 10 feet for many common theatrical firearms applications. Armorer guidance and manufacturer specifications for the specific ammunition must govern the minimum safe distance for each production.
Jon-Erik Hexum’s death demonstrated that even a single blank cartridge, pressed against the head, is lethal. Brandon Lee’s death demonstrated that even blanks can propel projectiles that are already in the barrel. Every barrel must be visually inspected by the armorer before each use.
Edged Weapon Safety
Theatrical edged weapons (swords, knives, daggers, axes, spears, and similar) are real weapons that are capable of causing injury, even when they are “stage” versions designed for theatrical use. Key safety principles:
- Staged combat choreography must be developed and supervised by a trained fight director or fight choreographer certified by the Society of American Fight Directors (SAFD) or an equivalent organization.
- Performers must be trained in staged combat techniques by a qualified fight director. Performing staged combat without training is the equivalent of driving a vehicle without a license.
- Edged weapons must be inspected before each rehearsal and performance. Blades must be examined for nicks, cracks, bent tips, and loose fittings.
- Edged weapons must be stored in sheathed or covered condition when not in active use. A sword left resting against a wall is an injury waiting to happen.
Storage Requirements for Stage Weapons
All stage weapons must be stored securely when not in use:
- Real firearms: must be stored in a locked container meeting ATF safe storage guidance when not in the direct custody of the armorer. The ATF recommends a gun safe or locking steel cabinet.
- Blank-only pistols and modified firearms: same storage requirements as real firearms.
- Edged weapons: locked storage or a secured props cabinet with a key accessible only to authorized props staff.
- Prop replica weapons (non-firing replicas): locked storage to prevent unauthorized access and to distinguish them from real weapons.
Transport of Firearms
Transport of real firearms, including theatrical prop firearms, is subject to federal and state law. Federal law (18 U.S.C. Section 926A) permits interstate transport of unloaded firearms in locked containers in private vehicles, separate from ammunition, when the person is legally allowed to possess the firearm in both the state of origin and destination. State laws vary significantly and may impose additional requirements. The production armorer is responsible for ensuring that firearms transport complies with applicable law.
Training Requirements for Cast and Crew
Every person who handles a weapon in a theatrical production must receive safety training appropriate to the weapon type before handling it:
- Firearms: safety training by the armorer covering the four rules, the specific firearm being used, blank ammunition hazards, and emergency procedures.
- Edged weapons: training by a certified fight director in the specific choreography.
- Prop replica weapons: training in the procedures for safe handling, storage, and use, even though the weapon is not functional.
Incident Response
If a weapons-related incident occurs during rehearsal or performance:
- Call 911 immediately.
- Secure all weapons. No weapon may be moved, modified, or cleaned until law enforcement has taken custody or authorized the action.
- Preserve the scene: do not move or remove anything from the area.
- Render first aid to any injured person while awaiting EMS.
- Do not make public statements to media. Refer all inquiries to the production’s designated spokesperson and legal counsel.
Key Takeaways
- There are no prop guns. Every firearm is a real weapon and must be treated as such at all times.
- A trained armorer is required for any production using real firearms. Only the armorer loads and unloads firearms.
- Blank cartridges can cause lethal injuries at close range. Minimum safe distances must be established by the armorer for each production.
- Staged combat with edged weapons must be choreographed and supervised by a certified fight director.
- All stage weapons must be stored in locked storage when not in the armorer’s direct custody.
- In the event of a weapons incident: call 911, secure all weapons, preserve the scene, render first aid.
References
Society of American Fight Directors. (n.d.). SAFD standards for stage combat. https://www.safd.org
SAG-AFTRA. (2020). General safety guidelines for theatrical and motion picture productions. SAG-AFTRA.
Bureau of Alcohol, Tobacco, Firearms and Explosives. (n.d.). Safe storage of firearms. https://www.atf.gov/firearms/safe-storage-firearms
Occupational Safety and Health Administration. (n.d.). General Duty Clause. OSH Act Section 5(a)(1). U.S. Department of Labor.
National Institute for Occupational Safety and Health. (n.d.). Preventing firearm-related injuries in entertainment. https://www.cdc.gov/niosh