Upgrading to LED Floodlights using existing Masts: Considerations

In this blog, we will explore the key considerations when deciding to repurpose your existing masts for an LED Floodlight retrofit.

Opting to reuse your masts can significantly impact the overall project cost, as masts (and the associated work on them) typically make up more than 40% of the total expenses. Additionally, reusing your masts can also help streamline project timelines. Typically, an LED Lighting upgrade can be completed within 1-2 weeks, but replacing masts could extend the project duration.

Here are the key factors to take into account:


Understanding LED Floodlights Weight vs Traditional Lighting Systems


When considering upgrading to LED lights and reusing your current masts it is important to understand the weight difference between LED lights and traditional lighting systems.


LED luminaires are generally lighter in weight compared to older traditional lighting such as metal halides. This is because LED luminaires use smaller components and do not require bulky fixtures or ballasts.

The weight reduction provided by LEDs can have significant benefits, especially when it comes to older masts that may have weight limitations. By switching to LED lights, you can potentially reduce the overall weight load on your masts, allowing for safer and more efficient operation.

Additionally, the lighter weight of LED lights makes them easier to install and maintain. This can save time and resources in the long run, as less effort is required to handle and transport the lights.


Assessing the Weight Capacity of Existing Masts


Prior to transitioning to LED Floodlights, it is essential to evaluate the weight capacity of your existing masts. Going beyond their weight limits could lead to structural issues or even collapse.

To determine the weight capacity of your masts, refer to the manufacturer's specifications or seek advice from a structural engineer. Factors such as material, height, and condition of the masts should be taken into consideration. It is crucial to confirm that your masts can securely bear the weight of the LED floodlights before moving forward with the upgrade.

If you are uncertain about the suitability of your masts, consider consulting your lighting supplier. They can conduct a non-destructive test (NDT) or other assessment to assess the condition of your masts effectively.


Conduct a visual inspection 


When conducting a visual inspection on your masts, it is important to look for obvious pointers that indicate the good health of your existing poles.


Signs of rust, leaning, and sagging cross-arms can be red flags that your masts may not be suitable for reusing during an LED Floodlight retrofit. Rust can weaken the structural integrity of the masts, while leaning or sagging cross-arms can indicate structural stress or damage. It is crucial to address these issues before proceeding with the upgrade to ensure the safety and longevity of your lighting system.


If you notice any of these signs, it may be necessary to reinforce or replace the masts to guarantee they last as long as your new LED Lighting system.


Consider Lightweight LED Options for your Masts - Like Midstream Luminaires


If your existing masts have weight limitations and cannot support standard LED floodlights, there are lightweight LED options available in the market such as our luminaires. These lights are specifically designed to minimise weight without compromising on performance.

When exploring lightweight LED options, look for floodlights that utilise lightweight materials such as aluminum or composite materials. These materials offer high strength-to-weight ratios, making them ideal for installations with weight restrictions.

Additionally, consider LED floodlights that have compact designs and integrated heat sinks. These features help reduce the overall weight of the lights while ensuring efficient heat dissipation, which is crucial for the longevity and performance of LED Floodlights.


If in doubt ask the experts 


If you have any doubts about the compatibility of your masts for reuse, don't hesitate to reach out to our team at Midstream Lighting. We are here to offer expert advice on your LED lighting upgrade - get in contact with us today!

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