Airports across New Zealand face growing operational expenses, and one of the most overlooked contributors is outdated airfield lighting. Traditional halide or incandescent systems drain energy budgets, require constant maintenance, and struggle to meet compliance standards under CAA Part 139.
These systems not only inflate power bills but also add indirect costs through downtime, inefficiency, and higher safety risks. The solution lies in a carefully scoped LED retrofit that balances compliance, energy savings, and reliability.
Auckland Airport’s recent LED runway lighting retrofit showed how a properly planned project can deliver measurable savings while maintaining high safety performance in low-visibility conditions. That project demonstrated that when airports define their scope, choose certified fixtures, and follow acceptance testing procedures, they gain both cost control and improved resilience.
This article provides a step-by-step checklist designed for New Zealand airports, with practical guidance that airport managers, facilities teams, and runway engineers can use to scope, procure, and deliver an LED retrofit that meets compliance while cutting long-term costs.
Scope: Define Goals and Constraints
Every retrofit should begin with a clear definition of objectives and limitations. Before issuing tenders, airport managers must establish expected availability, budget range, and operational restrictions.
For instance, how much downtime can be tolerated during night work? What budget band applies to procurement, and what are the key performance outcomes?
Key considerations include:
- Low-visibility minima: Airports must ensure that lighting performance supports safe operations during fog, rain, or other visibility-reducing conditions.
- Outage tolerances: Define how long a runway can remain inactive without disrupting flight schedules.
- Budget band and timeline: Outline a realistic procurement and installation schedule that works with airport finances and seasonal demand.
By mapping these factors, airports set realistic expectations, avoid scope creep, and prevent unnecessary delays. A well-scoped project reduces the likelihood of costly contract variations during implementation.
Regulatory Map: CAA Part 139 Requirements
Compliance with CAA Part 139 lighting regulations is non-negotiable for New Zealand airports. These rules specify photometric levels, fixture spacing, and colour standards, along with documentation requirements. Part 139 also includes Appendix E, which defines acceptance tests for intensity and uniformity.
What to review under Part 139:
- Photometric levels: Intensity, colour, and beam spread must meet minimum standards.
- Fixture spacing: Correct placement prevents dark spots and glare.
- Documentation: Installation and maintenance records must be audit-ready.
Working with a provider who understands Part 139 ensures that retrofits not only pass audits but also maintain long-term certification without rushed fixes or penalties. Aligning your plan with the regulatory framework from the start reduces compliance risks and avoids fines.
Survey: Baseline Photometric Measurements
A retrofit should begin with an accurate survey of existing lighting. Airports need to measure lux levels, uniformity, and glare at night under different weather conditions. These baseline results provide a comparison point once the LED system is installed.
Survey elements to capture:
- Lux and intensity readings across the runway.
- Uniformity ratios to determine if light coverage is even.
- Glare measurements to ensure pilot visibility isn’t compromised.
This data-driven approach allows operators to benchmark improvements post-retrofit. It also supports compliance documentation and provides transparency for stakeholders reviewing the effectiveness of capital spending.
Specify Fixtures: Photometrics and Ratings
Choosing the right LED fixtures is one of the most critical steps. Fixtures must deliver certified performance, withstand harsh conditions, and maintain lumen levels throughout their lifespan. Relying on supplier data alone is risky, so request independent photometric files and certification documents.
Fixture requirements:
- IES photometric files to confirm beam spread.
- Lumen maintenance curves (L70) showing expected lifespan.
- IP rating for protection against water and dust.
- Certified beam patterns for each application (taxiway, runway edge, approach).
For airports in New Zealand, where weather conditions vary widely, robust fixtures ensure longevity and reduce unplanned maintenance costs. Standardised testing data helps managers evaluate suppliers on more than price alone.
Control System: Monitoring and Diagnostics
LED lighting systems are only as effective as their monitoring platforms. Centralised control ensures that faults are logged, outages are flagged immediately, and hours of operation are tracked for maintenance planning.
Features to specify:
- Fault reporting dashboards for real-time status.
- Hours tracking to predict when replacements are needed.
- Audit logs for CAA inspections.
With predictive maintenance capabilities, airports reduce downtime and extend fixture life. Automated alerts prevent minor issues from escalating into costly outages, while also supporting transparency during regulatory audits.
Power Centre: Capacity and Redundancy
Many airports overlook the importance of their power centres during a runway lighting retrofit. Even the best LED fixtures fail if the supporting switchgear, UPS, and backup generators can’t provide stable power.
Steps to include:
- Assess switchgear condition for compatibility with LED loads.
- Review UPS capacity to maintain reliability during outages.
- Ensure generator tie-ins support continuous power.
Planning capacity upgrades upfront prevents emergency repairs later. A reliable and segregated power supply protects both safety and operational continuity during high-demand periods.
Acceptance Tests: Photometric Acceptance Criteria
Before signing off on any retrofit, airports must perform acceptance tests based on runway photometrics. These tests verify that the installed lighting matches design specifications.
Acceptance testing covers:
- Intensity and colour levels at multiple runway points.
- Uniformity ratios to check even light spread.
- Control response to validate dimming and monitoring functions.
Clearly defining acceptance criteria in the contract ensures accountability. It gives airports the right to request rectifications before final handover, protecting long-term performance and compliance.
Night Works: Logistics and Safety Plan
Executing an LED retrofit requires careful planning of night work. Runways must be temporarily closed, often for limited windows, and coordinated closely with Air Traffic Control.
Planning essentials:
- Closure schedules that minimise flight disruption.
- Access sequences for contractors and equipment.
- Safety controls include signage, barriers, and monitoring staff.
A comprehensive logistics plan reduces delays, protects worker safety, and ensures the airport returns to operation on schedule. Poorly managed night works can result in extended closures and loss of revenue.
Obstacles and PAPI: Visual Coordination
Runway lights are part of a broader visual environment. Retrofitting must ensure consistency with obstacle lights, approach aids, and PAPI (Precision Approach Path Indicator) systems.
Checks to perform:
- Contrast between PAPI and runway edge lights.
- Consistency of colour cues for pilots.
- Integration with obstacle lighting to preserve perception.
Ignoring these relationships can cause confusion for pilots, particularly in poor weather. Coordinating all visual aids ensures that retrofits improve safety rather than introducing new risks.
Maintenance Plan: Spares and Schedules
A well-executed retrofit includes a long-term maintenance plan. Without it, airports risk downtime from delayed spare parts or inadequate staffing.
Maintenance elements to include:
- Spare fixture kits provided during handover.
- Lead times for replacement parts.
- Preventive maintenance schedules with monthly labour hours.
Planning for maintenance ensures that the benefits of LED technology—such as longer lifespan and reduced failures—are fully realised. It also allows airports to forecast costs accurately.
Procurement Spec: Mandatory Contract Items
Procurement documents must clearly outline non-negotiable items. Without these, airports risk contractors cutting corners.
Mandatory inclusions:
- Warranty and performance guarantees.
- Factory acceptance testing (FAT).
- Commissioning report detailing compliance checks.
- Remedies for non-conformance to protect investment.
By writing these conditions into the contract, airport managers safeguard outcomes and hold suppliers accountable for performance.
TCO Modelling: Inputs and Sensitivity Checks
Total Cost of Ownership (TCO) modelling ensures financial viability. Airports should account not only for capex but also long-term opex savings.
Inputs to model:
- Capital expenditure for fixtures and installation.
- kWh rates for power consumption.
- Maintenance hours saved through longer lifespans.
- Downtime costs from closures.
Running sensitivity checks allows managers to forecast ROI and net present value across different energy and cost scenarios. Accurate TCO modelling strengthens the case for investment and helps secure board approval.
Handover: Training and Documentation
The final step in a retrofit is effective handover. Without training and proper documentation, airports may struggle to manage the new system.
Handover requirements:
- Maintenance manuals for all fixtures and systems.
- Staff training sessions to build operational knowledge.
- Monitoring login access to support remote control.
- 12-month defect rectification to cover unforeseen issues.
This process ensures a smooth transition from contractor to airport staff, reducing reliance on external support and improving long-term system sustainability.
LED: Your Way To Better Profits
Retrofitting with LEDs is about more than saving power—it’s about building safer, more efficient, and more profitable operations. By following this checklist, airports in New Zealand can align with Part 139 lighting requirements, deliver measurable LED energy savings airport NZ, and strengthen their operational resilience.
At Up N Atom, we work with airports nationwide to scope, install, and maintain LED runway lights NZ that meet compliance, reduce costs, and improve reliability. If you want to simplify your planning and reduce future risks, head to our website and request a quote. Let’s upgrade your airfield lighting system to a modern, efficient standard built for long-term success.
