High Mast Light for Airport Apron Lighting Renovation Project Case

 

Project Overview

Project Name: Regional Airport Apron HighMast Lighting Renovation 

Project Project Location: Southeast Asia regional airport 

End-user: Airport infrastructure management department 

Adopted Product: HRLUX Full Set High Mast Light (Complete package: hot-dip galvanized tapered pole, electric lifting system, 600W / 800W modular lamp heads) 

Site Profile: Mixed passenger & cargo apron, covering aircraft parking bays and ground service vehicle lanes. The site was equipped with outdated high pressure sodium high masts requiring full replacement. This tropical coastal area features high humidity and regular salt spray exposure. 

Project Scale: Supply and installation of 7 sets of 26 meter full high mast lighting systems. 

Project Cycle: 16 working days, covering site survey, Dialux EVO photometric simulation, factory fabrication, on site erection, lamp aiming and final acceptance.

Core Project Requirements

The airport maintains overnight flight turnaround services. Its legacy high pressure sodium lighting failed to satisfy ICAO apron lighting standards. The client listed these key requirements:

1.Replace aged high pressure sodium high mast systems. Deliver qualified horizontal ground illuminance plus sufficient vertical brightness on aircraft fuselage, helping ground crew conduct visual inspections safely at night.

2.Deploy a complete high mast package: galvanized steel pole, built in electric lifting hardware and modular LED lamp heads. Anti corrosion construction must withstand coastal salt spray.

3.Enforce strict glare control, reduce light interference for pilots and air traffic controllers, and cap unnecessary upward light spill.

4.Cut overall power consumption and minimize frequent high altitude maintenance work caused by the limited service life of traditional HID lamps.

5.Complete installation without long term apron occupation. All construction activities must fit inside airport flight operation windows.

Project Pain Points & Site Challenges

Before renovation, the old sodium lighting system on the apron created multiple operational bottlenecks:

1.High energy consumption & short service life: Conventional high pressure sodium fixtures draw large power. Severe lumen decay appears after short operation time, forcing teams to lower lamp panels repeatedly for maintenance.

2.Uneven light distribution: Wings and fuselages of parked aircraft create large shadow zones. Insufficient vertical brightness on aircraft surfaces made night visual inspection difficult for ramp crews.

3.Coastal corrosion risk: Salt laden humid air speeds up rust formation on ordinary steel poles and lamp housings, while seal aging triggers premature equipment breakdown.

4.Glare and light trespass: Uncontrolled upward stray light disturbed tower staff and pilots during night taxiing. The original setup failed to meet airport TI glare limits.

5.Strict construction constraints: Apron work can only happen between flight shifts. Long time occupation of aircraft parking stands was forbidden.

6.Compliance barriers: Airport projects require foundation load verification, lightning protection testing and aviation light approval prior to construction.

 

Customized Lighting Solution

2.1 Product Matching & Technical Parameters

HRLUX engineering team adopted our full set high mast lighting solution after completing Dialux EVO 3D apron simulation, taking aircraft shadow shielding and coastal corrosive atmosphere into consideration.

Important On site Implementation Notes：

1.Simulation must account for aircraft body shadow blocking to balance horizontal ground illumination and vertical fuselage brightness.

2.For coastal salt spray sites, regular inspection on hot dip galvanized pole surface is recommended.

3.Run no load test for electric lifting mechanism before lamp head installation, ensure anti fall safety device works normally.

4.Deploy mixed beam angles: narrow beam for long distance coverage, wide beam for ground service vehicle lanes.

5.Complete foundation load test, lightning protection inspection and aviation obstruction light approval before construction.

Regional Matching Layout Strategy:   Main aircraft parking bays: Install 800W lamp heads, mix 15° and 45° lenses to optimize vertical illumination for aircraft surfaces.  Ground service vehicle access lanes: Deploy 600W lamp heads with 90° wide angle lens to realize uniform ground lighting.  Each complete high mast set includes tapered galvanized pole, lifting unit, lightning protection assembly, aviation obstruction light and full mounting accessories.

 

2.2 Project Implementation Process

1.Site survey: Measure apron layout and foundation condition, collect airport CAD drawings, confirm available construction windows between flights.

2.Dialux EVO photometric simulation: Import aircraft 3D obstacle model, match mixed beam angle combination, generate apron lighting report compliant with ICAO standards.

3.Scheme final confirmation: Confirm mast quantity, power configuration, lens combination and installation position for every high mast point.

4.Factory production & inspection: Steel pole welding and hotdip galvanizing; lamp heads pass IP66 waterproof and hightemperature aging test before shipment.

5.Airport side construction: Foundation acceptance, high mast pole hoisting, lifting system debugging, lamp head installation and wiring. All construction works are arranged strictly within flight gaps.

6.Precision lamp aiming: Adjust lamp head projection angle according to simulation result to control upward stray light.

7.Acceptance & hand over: Test horizontal / vertical illuminance, uniformity and TI glare index; deliver IES files, simulation documents, material certificates and operation maintenance manual.

 

Core Product Advantages

 When compared with high mast projects assembled from separately sourced components, HRLUX full set high mast lighting delivers targeted value for airport apron projects:

1.One stop integrated delivery: Complete solution including galvanized steel pole, lifting mechanism, modular LED lamp heads and aviation obstruction lights. Clients avoid separate procurement of pole and lamps, cutting matching risks and shortening overall project timeline.

2.Coastal oriented anti corrosion system: Q355JR steel paired with internal external hot dip galvanizing (85 120 μm zinc layer), suitable for long term coastal salt spray outdoor environments.

3.Safe dual control lifting structure: Electric manual dual control lifting fitted with anti fall locking protection. Manual emergency operation works under power failure to reduce risks of high altitude maintenance.

4.Flexible modular lamp head combination: 600W / 800W modular lamp heads with multiple beam angle choices. Engineers can assign different optics for aircraft bays and service vehicle lanes within one lamp panel.

5.High grade environmental performance: IP66 & IK08 lamp head rating, L70 lifespan ≥50000 hours, greatly reducing annual maintenance frequency.

 

Project Acceptance Data & Operational Benefits

3.1 Post retrofit On site Test Result

Once installation and lamp angle calibration finished, field measurement meets ICAO airport apron lighting requirements:  Apron average horizontal illuminance: 42 lx，Uniformity Uo:0.62 Average vertical illuminance on aircraft fuselage: 31 lx  CRI Ra ≥83  Glare TI index ≤10, upward light spill is effectively controlled; no glare complaints from pilots and tower staff during night flight operation.

3.2 Economic & Operational Benefits

1.Energy saving performance: Compared to legacy high pressure sodium lighting system, overall power consumption dropped by 51%, annual electricity saving ≈ $11430 USD.

2.Maintenance cost reduction: Long life LED modules plus groundaccessible lifting design reduce high altitude repair tasks; annual maintenance expenditure decreased by 73%.

3.Operational safety improvement: Balanced horizontal vertical visibility optimizes night shift ground crew working condition and reduces ground handling operational risk.

4.Integrated supply benefit: Factory pre matching reduces on site assembly workload and shortens apron occupation time during construction.

5.Investment pay back period: Static pay back period calculated by electricity plus maintenance savings reaches approximately 2.7 years.

 

Customer Testimonial

“Our apron relied on old sodium high mast lights for years. We struggled with high electricity bills, poor vertical lighting and frequent corrosion failures. The full package high mast solution from HRLUX saved us a lot of component matching work. Hot dip galvanized poles work well in our coastal salt humid climate. Dialux simulation matches real site performance perfectly, and the apron’s night visibility meets our flight safety requirements.” — Infrastructure Project Manager, Southeast Asia Regional Airport

 

Project Summary

This airport apron full set high mast renovation case demonstrates the practical performance of HRLUX full set high mast lighting system under coastal airport operating conditions. Targeting typical apron site pain points: aircraft shadow interference, insufficient fuselage vertical illuminance, coastal salt fog corrosion, high power consumption and risky high altitude maintenance, this one stop integrated solution delivers galvanized anti corrosion steel pole, safe lifting mechanism and modular multi optics lamp heads. Factory pre assembly lowers on site matching risk. This project offers replicable engineering reference for regional airport aprons, large cargo terminals and open air comprehensive yard lighting projects worldwide.

 FAQ

Q1：What is the maximum height of the high mast light for airport apron?

A1：Our high mast light can be customized from 15m to 40m, matched with multi-angle LED modules to meet airport apron uniform illumination requirements.

Q2：Does the high mast light support lightning protection and surge protection?

A2：Yes. The whole set adopts integrated lightning protection and 10kV surge protection design, adapting to outdoor open-air airport environment.

Q3：What is the warranty period of HRLUX high mast light?

A3：5-year warranty for LED light modules and power supply. We provide remote technical guidance and spare parts support.

Q4：Can you provide Dialux lighting simulation report for bidding?

A4：Yes. We can supply Dialux simulation report, IES files and full set of certification documents for project bidding.

 

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