Location Mascot, Sydney NSW
Industry: Aviation / Aircraft Maintenance Infrastructure
Applications:
Aircraft maintenance hangar lighting, ground-level task illumination, high-bay aviation retrofit.
- Primo 40K LED Highbay 260 W with 60-degree precision optics
Tigerlight was engaged by Qantas Airways at the Qantas Jet Base Mascot in Sydney to deliver a high-performance lighting retrofit across multiple aircraft maintenance hangars.
The existing lighting infrastructure had become redundant and no longer met the operational lighting requirements necessary for safe and efficient aircraft maintenance activities.
Qantas engineering teams provided strict lighting design parameters to ensure the upgraded system would support compliant, safe, and highly visible working conditions for aircraft engineers operating beneath high-bay structures.
The project remains ongoing, with more than 500 luminaires supplied to date as additional hangar areas are progressively upgraded.
Key Outcomes
- 500+ Primo 40K LED Highbay luminaires supplied
- Designed to achieve a minimum of 400 lux at ground level across maintenance zones
- Compliant with AS1680.2.4 and aligned with CASA operational expectations
- Precision 60-degree optics delivered controlled illumination from mounting heights up to approximately 30 metres
- Ongoing staged retrofit within a live aviation maintenance environment
The Challenge
The lighting solution needed to:
- Deliver a minimum of 400 lux at ground level across critical aircraft maintenance areas.
- Maintain strong colour rendering performance to support inspection accuracy and detailed engineering work
- Comply with AS1680.2.4 and align with CASA operational expectations
- Provide effective, controlled illumination from extreme mounting heights of up to approximately 30 metres
- Retrofit efficiently within a fully operational aviation maintenance facility while minimising disruption
- The primary challenge was delivering high lux levels from significant ceiling heights without creating glare, excessive spills or uneven distribution across the hangar floor.
Lighting Strategy
Tigerlight selected the Primo 40K LED Highbay 260 W fitted with 60-degree precision optics to meet the project’s strict technical requirements.
The narrow optical distribution was engineered to project concentrated illumination from high mounting heights directly onto maintenance zones, ensuring the specified 400 lux minimum target was achieved at ground level.
This controlled beam approach maximised useful light delivery while supporting visual clarity and maintaining strong colour rendering for detailed inspection tasks carried out by Qantas engineering teams.
The Solution
Tigerlight supplied the Primo 40K LED Highbay 260 W as the core luminaire for the hangar retrofit program.
The 60-degree precision optics ensured effective vertical light projection from ceilings up to approximately 30 metres, delivering strong, uniform illumination across the aircraft maintenance floor.
The result was a fit-for-purpose aviation lighting solution that met Qantas’ strict engineering specifications while aligning with AS1680.2.4 requirements and CASA operational expectations.
Implementation
The retrofit program has been delivered in stages to align with Qantas’ operational schedule and minimise disruption within the live maintenance environment.
More than 500 luminaires have been supplied to date, with additional hangar zones continuing through progressive upgrade phases.
This staged approach ensures continuity of aircraft maintenance operations while systematically improving lighting performance across the facility.
Products Used
Key Results
Performance Outcomes
- 500+ Primo 40K LED Highbay luminaires supplied to date
- Minimum 400 lux achieved across key maintenance areas
- Compliance with AS1680.2.4
- Alignment with CASA operational expectations
Operational Improvements
- Enhanced visibility and inspection clarity for aircraft engineers
- High-intensity illumination delivered effectively from up to 30 metre ceiling heights
- Ongoing staged upgrade program supporting operational continuity
- This project demonstrates how Tigerlight’s Primo 40K LED Highbay delivers controlled, compliant and high-output lighting solutions for complex aviation maintenance environments requiring precision performance at extreme mounting heights.
