Case Study: Aircraft Warning Lighting for the UK’s Largest Electric Pylon

Location: Undisclosed – United Kingdom
Client: National Infrastructure Authority
Duration: 3 Weeks
Health & Safety: Zero incidents, no injuries, no property damage

 The Challenge

Airspace Lighting was entrusted with marking the UK’s tallest and most high-risk electric pylon with a robust aircraft warning light (AWL) system. Due to its structural height and proximity to aerial flight corridors, ICAO Type C Medium Intensity Lights were required to ensure full 360° visibility for aircraft.

In addition to meeting aviation compliance, the site posed several unique technical and environmental challenges:

  • The structure is located in an extremely corrosive and weather-exposed area

  • Strict electrical safety protocols were required, including maintaining a minimum 5-meter working distance from live conductors

  • Custom brackets were needed due to the pylon’s non-standard geometry

 The Solution

Our engineering team meticulously designed and delivered a complete lighting system featuring:

  • 10 x WL3000 Medium Intensity ICAO Type C Lights

  • Custom-manufactured brackets for secure mounting to the pylon’s unique form

  • Weatherproof and corrosion-resistant stainless steel junction boxes (x5)

  • Durable industrial-grade 550m cabling, fixed with precision both vertically and horizontally for safety and aesthetic consistency

  • A ground-level control system, including:2 x Heavy-duty transformers1 x Custom-built main control panel with water-resistant housing and physical guards for environmental protection

Special attention was given to routing and sealing all connections to prevent water ingress and extend the lifespan of the system in this harsh environment.

 Materials Used

  • 10 × WL3000 Medium Intensity AWLs

  • 5 × Stainless Steel Junction Boxes

  • 2 × Transformers

  • 1 × Custom-Built Control Panel

  • 550m of Industrial Cabling

  • Team of 5 Specialist Engineers & Climbers

 The Outcome

The system was installed successfully within the 3-week window, without any incidents or delays. It now provides continuous, ICAO-compliant visibility of the structure from all aerial directions, enhancing airspace safety in a critical infrastructure zone.

This project underscores Airspace Lighting’s ability to deliver technically complex and environmentally resilient obstruction lighting systems for the most demanding sites in the UK.
contact us