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 catwalks 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.
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.

Upgrading Walkways: 50% fewer fixtures for better efficiency.

mlti-optical pattern Nemalux industrial luminaires such as the MR series can significant reduce the cost of industrial walkway lighting. By choosing the correct optical profile, distance between luminaires can be increased significantly, reducing the number of luminaires required to illuminate the walkway
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.

Walkway lighting can contribute significant cost to plant operation due to the sheer number of lights, power consumption, and maintenance time that is lost opportunity to improve other important plant functions. Modern LED luminaires offer many advantages over legacy lighting that can dramatically reduce these costs.

Based on common practices that were developed for HID bulbs, the older luminaires are installed with a 25° to 45° tilt to project light forward and reduce spillage onto adjacent spaces. While modern LED luminaires with secondary optics solve this problem, this practice is unfortunately still being used on new projects as well as retrofits using LED lights.

New Lighting Practices Improve Illumination

– 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 or catwalk. The standard practice of installing light fixture every 6 meters can now be changed to an LED light with Type 1 beam profile every 12 meters, resulting in substantial cost and time savings.

– LED lights with Type 2 beam profile, full cut-off as well as 3,000K color temperature, provide a Dark Sky / IDA compliant solution for external staircases.

– LED lights with Type 3 beam profile adjacent to platforms 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.

Advantages of Secondary Optics

Secondary optics found on modern luminaires offer substantial improvements over traditional luminaires. The first HID bulbs developed many years ago offered poor lighting control. Due to their limitations, these luminaires were installed on poles with a 25° to 45° upward tilt to project light forward and reduce spillage onto adjacent spaces. While this legacy practice is no longer required with modern luminaires equipped with secondary optics which have zero tilt angle and meet dark sky compliance, industry practice has not kept pace with the times. Many operators still uncritically apply these legacy practices on both new projects as well as retrofits, even when modern LED lights with secondary optics makes it unnecessary.
In the diagram below, Nemalux XR zero-tilt, Dark Sky compliant luminaire is compared with a competitor’s model that does not have zero-tilt. Comparing the 50 lumens contour line, the XR gives an additional 9 feet of 50 lumens + light levels along the walkway, substantially reducing the number of fixtures needed to illuminate the walkway.

Nemalux vs Competition fixture graphic

Variety of Support Structures for Ease of Maintenance

Support structures can greatly enhance a luminaire’s functionality in a walkway application. While some modern luminaires such as the Nemalux XR, AR, and MR family already offer tremendous versatility by supporting multiple optical profiles and mounting brackets, some walkway scenarios still require an additional support structure to achieve the target illumination levels. Amongst the many possible support structures to complement a chosen luminaire are straight poles, articulated poles, handrail mounts, and more.

Common Use Case

Illumination of material transfer conveyor belts and adjacent walkways & catwalks.

Problem to Solve

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

Our unique solutions:

  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.
  2. 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
  2. Complementary lighting design
    • A free service to companies who do not have their own lighting engineering department
    • Can save many hours of consulting engineering time
  3. Packaged solutions
    • Integrated luminaire and support structure and pre-wired junction box
    • Ready-to-install

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

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

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Nemalux MR series industrial LED luminaire, HID replacement, built for industrial walkways, conveyor belts, platforms and staircases. Certified for hazardous location (class I division 2 / c1d2), marine (UL 1598), Dark Sky and DLC area lighting c/w Slip Fitter Yoke Mount (MR-SFY)

MR Series3,000-6,000 lumens, C1D2, c/w SLIP FITTER YOKE MOUNT  (MR-SFY): 6.55 kg | 14.7 lbs | Mounting Height of 8′ to 12′

Nemalux XR Series industrial LED luminaire, built for area lighting, walkways, platforms, conveyor belts, and staircases - hazardous location (class I division 2, c1d2 ), marine, Dark Sky and DLC approved c/w slip fitter yoke mount

XR Series8,000–20,000 lumens,  C1D2 c/w SLIP FITTER YOKE MOUNT (XR-SFY): 10.05 kg | 22.1 lbs | Mounting heights of 8′ to 25′

Walkway Brochure

 

 

Nemalux MR series industrial LED luminaire, HID replacement, certified for hazardous location (class I division 2 / c1d2), marine (UL 1598), Dark Sky and DLC area lighting c/w pole mount (MR-PM)
Nemalux XR Series industrial LED luminaire for area lighting - hazardous location (class I division 2, c1d2 ), marine, Dark Sky and DLC approved c/w pole mount
Nemalux MR series industrial LED luminaire, HID replacement, certified for hazardous location (class I division 2 / c1d2), marine (UL 1598), Dark Sky and DLC area lighting c/w wall mount (MR-WM)
Nemalux XR Series industrial LED luminaire for area lighting - hazardous location (class I division 2, c1d2 ), marine, Dark Sky and DLC approved c/w wall mount
Yoke Mount Nemalux MR series industrial LED luminaire, HID replacement, certified for hazardous location (class I division 2 / c1d2), marine (UL 1598), Dark Sky and DLC area lighting
Nemalux XR Series industrial LED luminaire for area lighting - hazardous location (class I division 2, c1d2 ), marine, Dark Sky and DLC approved c/w yoke mount
Nemalux MR series industrial LED luminaire, HID replacement, certified for hazardous location (class I division 2 / c1d2), marine (UL 1598), Dark Sky and DLC area lighting c/w hook pendant mount (MR-HK)
Nemalux XR Series industrial LED luminaire for area lighting - hazardous location (class I division 2, c1d2 ), marine, Dark Sky and DLC approved c/w hook pendant mount
NEMALUX MR Series Size Reference
XR Series Size Reference

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

Your Trusted Industrial & Hazardous Location Lighting Experts