Lighting Upgrades for Walkways, Catwalks, Platforms & Staircases in Industrial Facilities

Connecting sections of a plant as well as providing access to critical work areas in an industrial facility has long been accomplished by implementing a large number of walkways and platforms that can be located on the exterior or interior of a facility. While the use of specific structural elements and materials has long been a major focus during the design and upgrade process to improve the overall safety on-site, good lighting has at times been a rather challenging part of the project. Although the positive safety impact of a well-designed lighting strategy on workers has been well documented, the selection and implementation process can at times be a major challenge.

Advanced Optical Design Inside the Extremely Rugged MR Series Case

This article will address the specific use of secondary optics as well as support structures that can provide desirable illumination results while reducing cost as a major obstacle for new projects as well as retrofits.

Standard: Illuminating walkways, platforms, and staircases with conventional HID as well as most standard LED luminaires is typically achieved by installing a light fixture every 6 meters.
Nemalux: The use of advanced optics can allow for 12 meters spacing and deliver a 50% reduction in overall quantities, generating substantial cost and energy savings.

Pole top luminaires that are installed on straight as well as articulating poles or existing pillars are one of the most common methods of supporting luminaires that are located adjacent to walkways and platforms. With a minimum mounting height of approximately 2.4 meters this method provides relatively easy access for future maintenance while allowing adequate clearance for operators. Based on common practices that were developed for HID bulbs, the luminaires are installed with a 25° to 45° tilt to project light forward and reduce spillage onto adjacent spaces. Unfortunately, this practice is still being used on new projects as well as retrofits using LED lights.

Due to the reduced size of the light source with LEDs, the use of secondary optics provides a great opportunity to eliminate the need for tilting the light fixtures and substantially increases visual comfort by reducing or eliminating glare. Walking up to a bright light that is mounted relatively close to the work plane can create different degrees of discomfort with operators based on age and eye sensitivities. Forward throw optics can effectively illuminate walkways and platforms, while the use of full cut-off housing elements can reduce or prevent glare.

Some of the new practices that have shown great potential for improved illumination are:

  • LED lights with a properly designed Type 1 beam profile can achieve IESNA recommended light levels while reducing the number of lights required for a given walkway. The standard practice of installing light fixtures every 6 meters can now be changed to an LED light with a Type 1 beam profile every 12 meters, resulting in substantial cost and time savings.
  • LED lights with Type 3 beam profile adjacent to platforms to deliver target light levels while reducing light spillage behind the poles. With a 0° tilt angle, operators can comfortably conduct daily tasks while trip and fall incidents related to eye fatigue could experience a substantial reduction.
  • LED lights with Type 2 beam profile, full cut-off as well as 3,000K color temperature, provide a Dark Skye / IDA compliant solution for external staircases.

Special consideration should be given to distribution pattern selection, glare reduction lenses as well as potentially compromised ingress protection levels when using retrofit kits that allow the installation of new LED lights onto existing brackets such as top hats. Installing LED lights at 2.4 meters with a tilt angle of 25° or 45° can create visual discomfort when frosted / glare reduction lenses are not being used. Expected light levels can quickly be calculated with lighting design software such as Dialux Evo or AGI32 and can support the implementation process and overall customer satisfaction.

How can we help you?

We’d love to help with your industrial LED lighting solutions. Please feel free to contact our staff at any time.

Nemalux takes pride in designing and manufacturing industry leading industrial and hazardous location outdoor LED lighting solutions.

Nemalux Industrial | Staff
Sam Pogosian
CEO, Nemalux Inc.

Problem to Solve

  • Frequent Fixture Maintenance
  • Poor Light Quality & Distribution
  • High Costs

How we solve the problem(s) uniquely:

  1. Nemalux-Specific Fixture Design
    • High-pressure die-cast aluminum housing with marine grade alloy, designed to safeguard power supply and diodes from overheating.
    • Triple-layer, best-available, powder coat finish.
    • Polycarbonate lenses seal the enclosure to withstand direct impact, extreme vibration, and corrosive materials.
    • Nemalux Equalization Valve prevents internal condensation accumulation while maintaining an IP66/67 seal and hazardous location ratings.
  1. Higher Performing Optics
    • 10+ Optic options
    • Lumens delivered in the distribution pattern
  1. Mounting Options
    • Nemalux mounting brackets are over-designed to prevent stress fractures and subsequent failures.
    • Stainless steel fasteners are secured in place with thread locker to prevent loosening while allowing access for future upgrades.
    • Adapters are available reliably seal fixtures to existing mounts that are not being replaced.
    • For new installations, fixtures can be delivered pre-assembled on adjustable or fixed stanchions to reduce installation costs.
  1. CCT Options
    • Optional 3,000K LEDs with a high color rendering index ensure excellent vision in all weather conditions.
  1. Dark Sky Compliance

Common Use Case

Illumination of material transfer conveyor belts and adjacent walkways.

Illumination Recommendations for Safety and Operational Considerations (IESNA Handbook):

 

Conveyor Transfer Points

Average Horizontal Illuminance Recommendation: 50 Lux / 5 FC

Average Vertical Illuminance Recommendation: 50 Lux / 5 FC

Uniformity Ratio Recommendation (Max : Min) : < 5:1

 

Conveyor

Average Horizontal Illuminance Recommendation: 20 Lux / 2 FC

Average Vertical Illuminance Recommendation: 20 Lux / 2 FC

Uniformity Ratio Recommendation (Max : Min) : < 10:1

 

Active Walkway

Average Horizontal Illuminance Recommendation: 50 Lux / 5 FC

Average Vertical Illuminance Recommendation: 15 Lux / 1.5 FC

Uniformity Ratio Recommendation (Max : Min) : < 5:1

 

Inactive Walkway

Average Horizontal Illuminance Recommendation: 10 Lux / 1 FC

Average Vertical Illuminance Recommendation: 2 Lux / 0,2 FC

Uniformity Ratio Recommendation (Max : Min) : < 10:1

Outcome of the Solution (Why Choose Nemalux?)

  • Improved Site Safety
  • Better Visibility in all weather conditions
  • Reduced Maintenance with Superior Product Reliability
  • Dark Sky Compliance and reduced light trespass
  • Lower Cost; Faster Delivery; Greater Support

Products of Interest for Walkway, Platform, & Stairway Lighting Solutions

MR

The MR is a unique multi-functional, feature rich light fixture based on our rigorous design, prototyping, testing and refinement process. Using industry leading manufacturing practices, our engineers and industrial designers were able to produce a fixture that not only exceeds the expectations of an HID replacement, but establishes a new benchmark in versatility for industrial LED lighting.

XR

(If elevated light levels are required for increased visibility)

Nemalux’s XR is built on the same design philosophy as our previous multi-purpose LED lights that can address a wide range of challenging applications in the light and heavy industrial workplaces. XRs are factory programmed to offer light outputs ranging from 8,000 to 20,000 lumen. Auto-ranging power supplies allow operation on 120-277 VAC or 347-480 VAC. Optional 0-10V dimming provides further opportunities for fine-tuned illumination results based on facility and operator preference.

Click above to see our wide range of industrial LED lighting solutions and case studies.

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Nemalux Industrial