Airbus Hangar Lighting Upgrade Case Study – High-Performance LED Lighting Retrofit

Illuminate Pros, a leader in energy-efficient lighting solutions, partnered with Airbus at Brisbane Airport to deliver a large-scale aircraft hangar lighting upgrade. This project involved replacing outdated metal halide and fluorescent fittings with modern, high-performance LED hangar lighting systems, improving illumination quality, reducing maintenance, and achieving significant cost and energy savings.

The result demonstrates how Illuminate Pros successfully executed one of Australia’s most efficient aircraft light upgrades, setting a new benchmark for hangar lighting design and performance.

Project Objectives

• Energy Efficiency: Reduce overall energy usage and lighting-related operational costs.
• Sustainability: Decrease CO₂ emissions and support Airbus’ long-term environmental goals.
• Lighting Optimisation: Upgrade to the best LED high bay fixtures for aircraft hangars for improved visibility and safety.
• Maintenance Reduction: Lower maintenance requirements and downtime through durable LED technology.
• Compliance: Ensure the lighting system meets aircraft hangar lighting requirements and standards for aviation operations.

Facility Overview

The Airbus facility at Brisbane Airport includes two large aircraft hangars along with workshop, storage, and office areas. Before the upgrade, the lighting setup included:

• 400W and 1000W Metal Halide High Bay Lamps
• 36W T8 Fluorescent Tubes

These older fittings delivered inconsistent illumination, produced excess heat, and required frequent maintenance — common challenges across industrial lighting projects in Brisbane and aviation environments.

Key Outcomes

Energy and Cost Savings

Illuminate Pros conducted a detailed lighting assessment and designed a custom aircraft hangar lighting system optimised for energy efficiency and performance.

• Annual Energy Cost Savings: $82,000
• Energy Reduction: 61% reduction in energy use
• CO₂ Reduction: 105 tonnes annually
• Maintenance Savings: 76% reduction ($38,245 saved per year)

This shows how a well-planned hangar lighting upgrade can deliver measurable cost reductions and improved operational outcomes.

Return on Investment

• Payback Period: 1.7 years
• 7-Year ROI: 470%
• 15-Year Lifetime ROI: 787%
• Total Net Returns: $1.12M over the product lifespan

The lighting retrofit not only reduced ongoing costs but also provided substantial long-term financial returns, demonstrating the value of investing in LED lighting upgrades for industrial facilities.

Enhanced Illumination

The hangar lighting upgrade achieved a 108% increase in average lux levels across all zones, creating brighter and safer working environments. Aircraft surfaces now receive clear, uniform illumination, improving accuracy during maintenance, inspections, and safety checks.

This upgrade also improved visibility across workshops and storage areas — a key factor for lighting design upgrades and maintenance in large-scale industrial and aviation facilities.

Lighting Solutions Delivered by Illuminate Pros

Illuminate Pros designed and installed a tailored aircraft hangar lighting system using advanced, high-performance LED fittings suitable for high ceilings and large spaces:

• 120W LED Fixtures: Replaced 400W and 250W metal halide lamps. Delivered high brightness and reduced glare with lower energy consumption.
• 240W and 300W LED High Bays: Replaced 1000W fittings to achieve powerful, glare-free light across the hangar floor. These are among the best LED high bay fixtures for aircraft hangars, offering high lumen output, wide coverage, and long lifespans.
• 16W LED Tubes: Replaced 36W fluorescent tubes in office and workshop areas to improve efficiency and light consistency.
• Daylight Control System: Integrated lighting sensors to automatically adjust illumination based on natural light, further reducing energy use during daytime operations.

This lighting configuration not only improved brightness but also met aircraft hangar lighting standards, ensuring safety and performance for precision aviation work.

Environmental Impact

The lighting upgrade helped Airbus achieve a major sustainability milestone:

• CO₂ Reduction: 105 tonnes per year
• Equivalent to removing 22 vehicles from the road annually or planting 735 trees each year

Illuminate Pros continues to demonstrate how LED hangar lights can deliver significant environmental benefits while maintaining optimal performance in large industrial environments.

Financial Benefits

Project Cost: $142,733
Total 15-Year Savings: $1.26M
Net Returns: $1,123,689

By upgrading to an energy-efficient lighting system, Airbus secured immediate and long-term financial gains while improving safety and compliance across its operations.

Client Testimonial

“Illuminate Pros’ LED lighting solutions have completely transformed our facility. The hangars are now brighter, safer, and far more energy-efficient. The savings exceeded expectations, and the installation process was smooth and well-managed. We highly recommend Illuminate Pros for any aircraft hangar lighting upgrade or industrial lighting retrofit.”
– Airbus Facility Manager

Why Choose Illuminate Pros?

Illuminate Pros is one of Australia’s trusted industrial and aircraft hangar lighting specialists. From lighting design upgrades and maintenance to full hangar lighting solutions, we combine technical expertise with energy-saving innovation to deliver reliable results.

Whether your facility is in Brisbane, Perth, or Melbourne, we provide:

• Custom-designed LED hangar lighting systems for aviation, defence, and industrial facilities
• Lighting retrofit and upgrade services for warehouses, workshops, and manufacturing plants
• Expert guidance to meet aircraft hangar lighting standards and requirements

Get Started with Illuminate Pros

Ready to upgrade your facility with high-performance, energy-efficient lighting?

Contact Illuminate Pros to arrange your lighting audit and upgrade proposal — tailored to your site layout, illumination needs, and energy goals.

Call 1300 878 874 or submit an enquiry through our website to schedule your consultation.

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FAQs

Q1. Why choose LED lighting for aircraft hangars?

LED lighting is ideal for hangars due to its high lumen output, long lifespan, and energy efficiency. Large indoor spaces like hangars require powerful illumination that’s consistent and low-maintenance. In this upgrade, LED high bay fittings were installed to provide clear, even lighting across wide open floor areas — improving visibility, safety, and operational performance while reducing energy use.

Q2. Why is good Aircraft Hangar Lighting so important?

Aircraft hangars require precise, high-performance lighting to support maintenance, inspections, safety checks, and aircraft movement. Poor lighting can result in operational delays, safety risks, and reduced visibility for critical tasks. A well-lit hangar improves both productivity and workplace safety, ensuring staff can perform tasks accurately — day or night. In this project, upgrading to LED lighting created a much brighter and safer working environment without increasing energy costs.

Q3. What are the best LED Light Fixture for Aircraft Hangar Lighting ?

The best LED fixtures for hangars are LED high bay lights designed for high ceilings and wide-area coverage. Look for fittings with a high lumen output, wide beam angle, and IP ratings for dust or moisture resistance. For this upgrade, industrial-grade LED high bays were selected to deliver uniform light distribution, long operating life, and minimal maintenance — ideal for the scale and demands of aviation environments.

Q4. What are the best led light fixture for aircraft hangar lighting?

For high-ceiling aircraft hangars, the most effective fixtures are UFO-style or linear LED high bays, which provide powerful, glare-free lighting from above. These fixtures ensure strong vertical and horizontal illumination, improving visibility on aircraft surfaces and work areas below. At Illuminate Pros, we recommend commercial-grade LED high bays with high CRI and long lifespan, ensuring efficiency and compliance with aviation lighting standards.

Q5. How can you request a lighting upgrade proposal for your hangar or industrial facility?

You can book a consultation by calling Illuminate Pros or submitting an enquiry through our website. Our team will assess your current setup, discuss usage requirements, and provide a tailored LED upgrade plan — including product specs, installation scheduling, and energy-saving projections.

Q6. What type of lighting is used in hangars with high ceilings?

LED high bay lighting is typically used for hangars, offering powerful output and wide beam angles for large vertical and horizontal coverage. These lights are mounted at height but still deliver optimal brightness to the ground level – ideal for aircraft storage and maintenance environments.