Our Refurbishment Concept

We would briefly like to explain our refurbishment concept for inset lights: Many years ago, we started our cooperation with Düsseldorf Airport. The task was to protect steel and aluminum lights, types 5NQ51 and 5NQ52 and 5NQ56 / 58 / 59, against corrosion.

Due to our refurbishment concept/procedure we succeeded in protecting steel and aluminium lights against corrosion. During the research of possible causes for corrosion we have noticed the following:

1. Mechanical Load

The anodized coat of the aluminum lights is damaged by abrasion and movement in the “lower-part”.

2. Chemical strain

– Corrosive acetate in de-icing fluids
– Kerosene
– Icing salts
– Chemical reactions of the aluminum with concrete (depending on the composition of the concrete and aggregates)
– Rubber abrasion with sulfur deposition and thermodynamic strain (cohesion and adhesion by aircraft wheels)

3. Electrolysis

Due to the DC component of controller-based series an electrolysis is produced in an inset light which is filled with icing salts and water. In this electrolysis, a material migration occurs between the anode and cathode (indicated by the polarized material remains of various kinds). The result is an oxidation.

4. Damage impact on the functionality of the high-performance inset lights

In case of damage to the sealing surfaces by corrosion, refurbished lights became leak again within a very short time.  Thereby the process mentioned above is repeated after each maintenance of the lights. Valuable/high quality installation/mounting parts are damaged again with the result of high costs. When cleaning a defective inset light with an unsuitable blasting method, this also leads to damage of the anodized coating. Even wrong dose application of bead blasting methods with plastic results in damage.

In our opinion, it is essential to apply a corrosion protective coating, to mend sealing surfaces on inset lights with open and closed construction. However, it should be noted, that the corrosion of the inset light had progressed so far, a refurbishment is no longer possible.

Based on the experiences of the past years, we are proud to offer a refurbishment concept that brings back inset lights to an almost new condition. As the light measurements in the last years have shown, the refurbished high-performance inset -lights reach the values of new inset lights of the respective manufacturer. In particular our development and application of the prism polish leads to excellent results.
This refurbishment concept saves enormous costs for our customers.

  • Reuse of the prisms (polish up to 7 times possible).

  • The coating prevents corrosion of the sealing surfaces. As a result, inset lights remain durably waterproof.

  • Damage to the built-in parts (prisms, color filters, reflectors, threads, screws, contact bridges, etc.) by water are prevented.

  • Depending on the condition, damaged parts can be repaired/maintained and then be used again.

  • Old runway lighting systems can be brought back to their original performance for low costs.

  • The replacement of inset lights is not necessary in most cases (break out of the installation shells, as well as new drilling is an exception).

  • Consequences of pollution caused by jet blast and rubber abrasion are significantly smaller on refurbished prisms. Thus, the period to the next cleaning is extended.

  • Older, still intact bulbs can remain for a longer period when the prisms are in good condition.

Used underfloor fire after use at the airport

Our refurbished fire from Siemens