Article - March, 2016 By LarsonElectronics.com

Benefits of LEDs in the Commercial Crane Sector

These days, light emitting diode (LED) technology is being used to support busy crane operations. Traditional practices of using halogen and metal halide lamps for illumination forces businesses to invest in costly maintenance work. By replacing or converting the fixtures to LEDs, establishments can make the jobsite safer, while adhering to strict lighting regulations.

Based on industry statistics from Konecranes, conventional lighting systems account for 50-90 percent of the electricity used by a crane. The large allotment in electricity usage is designed to address compliance in lighting regulations set forth by various governing institutions, such as the Federal Aviation Administration (FAA), International Civil Aviation Organization (ICAO) and the Federal Communications Commission (FCC). The guidelines were created to prevent disruption in commercial aviation operations. Due to the towering height of cranes, adequate lighting must be applied to provide early warning notifications for planes, ground crews, operators and pedestrians. .

Obstruction lighting in the crane sector is essential. Such systems are designed to mark tall structures, including towers, antennas and cranes. The lights notify airplanes and ground crews on the location of the machines in real-time. When in use and outside of operating hours, cranes must be marked with lights. The arrangements of the lights on the equipment requires the structure to be marked from “every angle of in azimuth.” Furthermore, the height of the crane must be taken into consideration when determining the number of light levels during operation.

Below expounds on the different types of lighting levels based on structural height:

• H < 45m: One level of low intensity obstruction lights shall be used
• 45m < H < 105m: Two levels of obstruction lights shall be used: top level with medium intensity, intermediate with low intensity
• Instant toggling
• No toxic chemicals
• 105m < H < 210m: Four levels shall be used: top with medium intensity, 1st intermediate with low intensity, 2nd intermediate with medium intensity, lower level with low intensity

The number of lights required per level is subject to the following guidelines:

The number of lights required per level is subject to the following guidelines:

• Top level: One to three obstruction lights shall be used on the top level: at the top and, if necessary, at jib and counter-jib
• Other levels: One or two obstruction lights shall be used on each level of the tower: the structure has to be indicated from every angle in azimuth

One of the main hurdles associated with crane lighting is maintenance. Previously, most businesses relied on metal halide and halogen fixtures for illumination. This practice resulted in meticulous maintenance, as halogens come with an average lifespan of 1-2 years. By comparison, LEDs can last up to 5-6 years under optimal operating conditions. To streamline maintenance work on LED units, manufacturers have developed modular LED fixtures. This new design and manufacturing trend allows workers to replace non-working parts of the equipment, as opposed to replacing the entire fixture during failure.

LEDs support a solid-state design, which reinforces its sturdy properties. The fixture can withstand rough treatment and extreme weather conditions better than conventional units that rely on glass casings, loose parts and toxic chemicals. Such features allow the lamps to thrive in unpredictable outdoor environments, where cranes are usually installed. When it comes to compliance, the initial ruling for the application of crane lighting involves the requirement of obstruction lighting for all temporary or permanent structures that exceed an overall height of 200 feet above ground level (AGL). External commercial lighting sources are not sufficient in meeting this requirement.

Upgrading to LED lights can help businesses control operational costs. In the case of port container cranes, such fixtures are exposed to constant vibration, moisture and corrosion. Under extreme environments, traditional lights would fail prematurely or require around-the-clock upkeep (which results in high labor and material costs). An example of the economical advantages of using LEDs during crane operations comes from a Phoenix Products study. The company cited that outfitting a rubber tired gantry (RTG) crane with LED floodlights and area lights resulted in a reduction of annual operating costs by $5,000 per RTG crane. Businesses that deploy 50+ RTGs on a site can save as much as $250,000 per year, just by switching over to LED fixtures.

Below is a shortlist of LED crane lighting products available from Larson Electronics:

• High output crane and rough service LED fixture (300 watts; 25,000 lumens)
• Crane LED flood light (150 watts, IP67 waterproof rating; 13,000 lumens)
• High bay LED crane lighting (600 watts, stainless steel brackets; 78,000 lumens)
• LED crane and rough service fixture (1,000 watts; 29,580 lumens)
• Red crane warning laser (Five watts, IP54 approval rating)
• Portable LED floodlight system crane lighting (1,600 watts; four LED lights; 208,000 lumens)

At Larson Electronics, we do more than meet your lighting needs. We also provide replacement, retrofit, and upgrade parts as well as industrial grade power accessories. Our craftsmen can custom build any lighting system and/or accessories to fit the unique demands of your operation. A commitment tohonesty, quality, and dependability has made Larson Electronics a leader in the lighting and electronics business since 1973. Contact us today at 800-369-6671 or message sales@larsonelectronics.com for more information about our custom options tailored to meet your specific industry needs.