Yes, existing masts can often be retained when upgrading airport apron lighting. The important questions are whether they can safely support the new equipment and whether their positions allow the lighting design to deliver the performance the apron needs.
Replacing the floodlights does not automatically mean replacing everything beneath them. For airports with suitable infrastructure, a retrofit can reduce civil works and make the upgrade easier to plan around daily operations.
Here’s what needs to be considered before deciding which masts to keep.
The first step is to assess the condition and capacity of the existing masts, foundations and mounting arrangements.
Age alone does not tell you whether a mast needs replacing. Equally, a mast that looks sound may have corrosion or damage that needs closer investigation.
A structural assessment should consider:
These checks should be carried out by a suitably qualified structural or civil engineer.
Lighter floodlights can reduce the load on existing masts and make them easier to retain during an upgrade. The windage of the new fittings also needs to be considered.
Windage describes the area a floodlight presents to the wind. Its size, shape and mounting angle all affect the wind loading on the mast.
Both weight and windage should be assessed for the proposed floodlights, brackets and mounting arrangement to confirm that the mast can safely support them.
A mast may be structurally suitable and still be in the wrong position for the lighting required today.
Aircraft stands may have been reconfigured since the original installation. Larger aircraft, new equipment or changes to ground operations can also affect where light is needed and where shadows occur.
The lighting design should assess the existing mast locations and heights against the current stand layout. It needs to consider:
Different optics and aiming arrangements may allow the existing positions to work well. Where they cannot, the project may need additional masts or changes to part of the layout.
Sometimes, but the lighting design should determine that.
Two floodlights with similar wattages can distribute light very differently. Matching the number of existing fittings does not show whether the new system will provide suitable coverage, uniformity or glare control.
Keeping the masts does not necessarily mean keeping all the electrical equipment.
The existing supply, cabling, protection and controls need to be assessed for the proposed installation. That includes their condition, electrical compatibility and any changes needed for dimming or monitoring.
Driver location also matters. Remote and integrated drivers have different implications for cabling, mounting and maintenance access.
These details are best resolved during the design stage, so the installation scope is clear before work begins.
Replacement may be needed where a mast has significant deterioration, cannot support the proposed equipment or is poorly positioned for the current apron layout.
It does not have to be an all-or-nothing decision. A project may retain suitable masts, refurbish some elements and replace or add others.
Maintenance access should also be considered. A mast worth retaining structurally still needs a practical arrangement for inspecting, cleaning and maintaining the new lighting.
Gather the existing mast drawings, inspection records, stand layouts and details of the current lighting system. A site survey can then establish what is there and identify any gaps in the information.
From there, structural assessment and lighting design can establish which masts can be retained and what changes are needed.
At Midstream, we assess retrofit opportunities as part of the lighting design. If you’re considering an apron lighting upgrade, send us your stand layout and existing mast information. We can help you work through the options.