For airport electrical engineering and operations teams, replacing apron floodlights means fitting the work around a busy flight schedule.
The upgrade can often be carried out in phases, with individual stands or work areas temporarily taken out of use while the rest of the apron remains operational. Each phase needs enough time to safely replace, aim and test the floodlights before the area is handed back.
Planning starts with understanding which areas will lose lighting during the work, when access is available and whether temporary lighting will be needed.
Here are the main points to consider before work begins.
Working through the apron one mast at a time may seem straightforward. However, the light from one mast can cover several stands, and a stand may receive light from more than one direction.
Disconnecting a mast could therefore affect areas outside the immediate work zone.
The phasing plan should identify which floodlights will be unavailable at each stage and how this changes the lighting across the areas that remain in use. It should also consider the combined effect of the old and new lighting during the changeover.
Where a phase leaves an operational area without suitable illumination, the plan needs to provide temporary lighting, change the working sequence or take the affected area out of use.
That depends on the installation.
On some projects, new equipment can be installed alongside the existing system, allowing the old lights to remain in use until the changeover. On others, the same brackets, mast head or electrical circuits are needed for the replacement fittings.
The electrical survey should establish which circuits can be isolated independently and which areas share a supply. A stand closure alone does not make the electrical work safe. Isolation, testing and access arrangements need to be agreed before anyone starts removing equipment.
It is also worth confirming how much of each phase can be completed before the existing lights are switched off.
Temporary lighting can help maintain coverage during installation, but it needs its own assessment.
A mobile Lighting tower should be positioned and aimed to suit the area being used. Its location must also allow for aircraft clearance, vehicle routes, ground equipment and access for refuelling or maintenance.
Consider:
Temporary lighting must also avoid confusing or obscuring aeronautical ground lights. The CAA’s safeguarding guidance highlights these considerations for lighting around aerodromes.
Lighting used by the installation team should be assessed separately. Illuminating the work area does not necessarily provide suitable lighting for an aircraft stand.
The time available on the apron needs to cover more than fitting the new floodlights.
The engineering team needs time to move equipment into position, establish the work area and carry out electrical isolation before installation begins. Time is also needed to test the equipment, clear the site and hand the area back.
For each phase, allow for:
Preparing equipment beforehand can make better use of the working window. Floodlights, brackets, drivers and cables should be checked against the design and labelled for their intended positions.
Aircraft schedules change. Equipment can develop faults, and weather may prevent work at height.
The electrical engineering and operations teams need an agreed response if a phase takes longer than expected or cannot start as planned.
That might mean restoring the existing lighting, using an assessed temporary arrangement or keeping the affected stand out of use. The appropriate option depends on the work completed and the airport’s operational needs.
Agree the decision points in advance. If a stand must return to service at a set time, the team needs to know when to stop installation and begin making the area ready.
New floodlights switching on is only the first check.
Before an area is handed back, confirm that the equipment is secure, the required lighting is available, controls operate as intended and the work site is clear. Tools, fixings, packaging and cable offcuts all need to be accounted for to reduce the risk of foreign object debris.
Agree the checks required for each phase, including any restrictions that remain in place. Where work is completed during daylight, suitable access must also be arranged for aiming and night-time verification.
The completed system should then be commissioned against the approved lighting design. This includes measuring lighting levels and uniformity, checking controls and recording any adjustments.
Our Photometric Guide explains how to measure apron lighting and record the results, helping your team compare the installed performance with the design.
Once the upgrade is complete, the airport needs clear records of what has been installed and how it should be operated and maintained.
These should include:
If the new system introduces dimming, zoning or monitoring, allow time for the people who will use it to become familiar with the controls.
A workable installation programme brings the lighting design and airport operations together. It sets out what can be completed in each window, how lighting will be maintained and what must happen before an area returns to use.
At Midstream, we can help assess the lighting implications of a phased upgrade, including the use of existing infrastructure and any temporary lighting needs.
If you’re planning a project, speak to our team about your apron layout, current lighting and available access windows.