Project Overview
●Project Date: December 2019
●Project: Tangshan Beifang Coal Storage Yard Lighting Project
●Application: Large-Area Lighting for an Open-Air Coal Storage Yard
●System: 30 m Mechanical-Lowering High Mast Lighting System
●Quantity: 4 Sets
●Delivery: 18 Days
This project provides large-area lighting for coal stacking, loading and unloading, material handling, and vehicle movements at an open-air coal storage and handling yard in Tangshan.
The site covers a large, unobstructed working area where high-mounted lighting is required for wide-area coverage. Coal dust, strong winter winds, low temperatures, and seasonal snow also place additional demands on structural stability, corrosion protection, and maintenance access.
Four 30 m high masts with mechanically lowering luminaire rings were supplied. The lowering system allows luminaires to be serviced at ground level, reducing the need for work at height.
Project photos document mast fabrication, on-site lifting, and the completed installation.
Challenge 1 | High Mast Structural Stability in High-Wind Conditions
The coal yard is open and largely unobstructed, leaving the 30 m high masts exposed to strong winter winds and frequent gusts.
Multiple floodlights are mounted at the top of each mast. The luminaire ring has a relatively large projected area, increasing wind load on the upper mast. Coal dust buildup and winter snow accumulation can also add to the load carried at the top of the structure.
→Engineering Response
To account for wind, dust buildup, and snow loading:
◎The mast is fabricated from Q355B structural steel. Structural calculations include local basic wind pressure together with additional loads from dust buildup and snow, with checks on mast strength, top deflection, and overturning stability;
◎Mast section dimensions, wall thickness, and taper are optimized for the 30 m mounting height and top load to improve bending resistance;
◎The luminaires are arranged radially around the ring to provide wide-area coverage while reducing large horizontal surfaces where coal dust can accumulate. The layout also helps distribute wind loads more evenly and reduce eccentric loading;
◎The luminaire-ring flange, supporting members, and upper connection points are reinforced to improve stability under repeated wind loading and additional service loads.
Challenge 2 | Corrosion Protection in Dusty and Low-Temperature Environments
Coal yards are continuously exposed to airborne dust. When coal dust settles on steel surfaces and combines with moisture, the risk of surface corrosion increases.
Low winter temperatures and repeated freeze-thaw conditions add further exposure for outdoor steel structures.
→Engineering Response
The corrosion protection system was designed for long-term outdoor service:
◎The mast is hot-dip galvanized in accordance with GB/T 13912, which adopts ISO 1461 with modifications;
◎Minimum zinc coating thickness is ≥85 μm;
◎Flanges, weld areas, stiffeners, and other structural details receive full galvanizing protection to reduce the risk of localized corrosion;
◎Both the internal and external surfaces of the mast are hot-dip galvanized, reducing the risk of internal corrosion caused by moisture and condensation.
Challenge 3 | Wide-Area Lighting and Ground-Level Maintenance
The coal yard requires continuous lighting across a large operating area. A 30 m mounting height provides the elevation needed for broad lighting coverage.
With a fixed luminaire arrangement, however, lamp replacement and routine servicing would require access equipment and work at height.
→Engineering Response
A mechanical lowering system was selected to simplify maintenance:
◎The luminaire ring can be lowered to ground level for inspection, lamp replacement, and routine servicing;
◎This reduces reliance on aerial work platforms or other high-level access equipment;
◎Multiple floodlights are arranged around the ring to provide broad coverage across the working area;
◎The lowering system incorporates limit and locking mechanisms for controlled operation and secure positioning.
Challenge 4 | Fast Delivery for Continuous Operations
The coal storage and handling facility remained operational during the project, so on-site work had to be kept as short as practical to limit disruption to material handling and vehicle movements.
→Engineering Response
A factory-prefabricated, on-site lifting approach was used:
◎Masts, luminaire rings, and lowering mechanisms were fabricated, galvanized, pre-assembled, and inspected at the factory;
◎Site work was mainly limited to lifting, positioning, flange connection, and system commissioning;
◎Factory preparation reduced on-site fabrication and shortened the installation window;
◎The complete project was manufactured and delivered within 18 days.
Four 30 m mechanical-lowering high masts were installed at the Beifang coal storage yard.
The completed system provided:
■Wide-area lighting for open-air coal handling and yard operations;
■Ground-level access to high-mounted luminaires for easier and safer maintenance;
■Hot-dip galvanized protection suited to dusty, low-temperature outdoor conditions;
■Reduced on-site installation work through factory prefabrication and coordinated delivery.
The project demonstrates our capability to engineer and deliver high mast lighting systems for heavy industrial yards where wind loading, wide-area illumination, maintainability, and short installation windows are key project requirements.
This project demonstrates our capabilities in:
▲Structural design and wind-load verification for tall lighting structures in exposed industrial sites;
▲Corrosion protection for dusty, cold-weather outdoor environments;
▲Mechanical-lowering luminaire systems for ground-level maintenance;
▲Factory prefabrication, rapid site installation, and short-cycle project delivery.
These solutions can be applied to coal yards, ore stockyards, bulk material terminals, and large industrial storage and handling areas requiring wide-area operational lighting.
