The difference between new terminal lighting and a retrofit project lies primarily in the approach, not in the end result. In new construction, the complete lighting system is designed and installed from the ground up. In a retrofit, existing infrastructure, masts, and cabling are reused and fitted with modern LED fixtures. Which approach is most suitable depends on the condition of the existing installation, the available budget, and the operational requirements of the terminal. The questions below will help you make the right choice for your situation.
When is a retrofit approach more suitable than new construction?
The existing infrastructure plays the main role in this. If the masts, foundations, and cabling are structurally still in good condition and the lifespan of those components has not yet expired, replacing only the luminaires yields the greatest savings — with the least disruption to operations. That is particularly relevant for Ports and terminals that run 24/7 and cannot afford prolonged downtime.
A retrofit is also a logical choice when an organization wants to make its operations more sustainable step by step. By modernizing the existing installation in phases, you spread the investment over several years without having to completely redesign the site layout.
New construction is more sensible when the existing masts are outdated or corroded, the light point height no longer complies with current safety requirements, or when the site layout has changed significantly. In that case, a completely new design offers more flexibility and a better foundation for the long term.
What are the technical differences between both approaches?
Design freedom is the most decisive difference. In a new lighting project, you choose the luminaire mounting height, the position of the poles, and the type of fixtures entirely based on current lighting calculations. With a retrofit, you work within the limits of the existing infrastructure — the fixtures must match the existing connections, the load-bearing capacity of the poles, and the existing cable diameters.
Technically speaking, a retrofit also involves additional considerations:
- Compatibility of the new luminaires with the existing cabling and switching systems
- The condition of the existing masts and connections, including corrosion and fatigue
- Adjustment of control currents or DALI systems if dimming functionality is added
- Thermal management, because LED fixtures have different thermal properties than conventional lamps
- IP and IK ratings of the new luminaires must match the local environmental conditions
With new construction, these limitations do not apply. All components are designed to work together, resulting in optimal light distribution and a longer service life. For environments with extreme conditions — such as aggressive corrosion whether due to sea air or chemical exposure—that degree of technical freedom is a significant advantage.
How much does a retrofit project cost compared to new lighting?
In most cases, a retrofit is significantly less expensive than new construction, simply because the largest cost items—foundations, towers, and main cabling—do not need to be rebuilt. The savings on civil engineering work alone can account for a large portion of the total project costs for new construction.
Yet there are situations where the initial cost savings of a retrofit turn out to be less favorable in the long run. If the existing poles need replacement within a few years, you end up paying twice for labor and installation costs. A thorough technical inspection prior to making a choice is therefore essential.
When evaluating costs, also consider available subsidies and tax incentives. Energy-efficient LED lighting may be eligible for the Energy Investment Allowance, which can significantly reduce the net investment for both retrofits and new construction. Be sure to get all the information you need on this before making a final decision.
What risks are associated with a retrofit that new construction does not have?
The biggest risk is that hidden defects in the existing infrastructure only come to light during implementation. Corroded cable trays, weakened mast bases, or outdated control cabinets can delay the installation and unexpectedly drive up costs. In new construction, this risk is practically nonexistent because all components are new and pre-specified.
Other risks of a retrofit include:
- Insufficient load-bearing capacity: Existing poles are not always designed to support the weight or wind loads of modern LED fixtures with larger optical surfaces.
- Electrical incompatibility: Older installations are sometimes unsuited for the power characteristics of modern LED drivers.
- Unexpected asbestos issues: Older industrial facilities may contain asbestos-containing materials, which entail additional remediation costs.
- Suboptimal light distribution: If the pole positions are not ideal, the new lighting can be technically perfect yet still fail to achieve the desired lighting levels.
A thorough preliminary measurement and technical inspection of the existing installation is not an unnecessary luxury during a retrofit, but a necessary step to avoid surprises.
How does the engineering phase proceed in a new lighting project?
Everything starts with a detailed analysis of the site layout, operational requirements, and applicable standards for the type of location. Based on this, lighting calculations are performed to determine the optimal positioning of light points, the required light intensity, and the uniformity across the site.
The engineering phase typically includes the following steps:
- Survey of the surroundings, including obstacles, driving routes, and work zones
- Lighting design based on standard requirements for the type of terrain
- Selection of luminaires, masts and foundation types
- Electrical design, including wiring, control panels, and any dimming systems
- Coordination with involved parties such as structural engineers, installation contractors, and the client
- Drafting a phased implementation plan that ensures operational continuity
During a retrofit, the engineering phase is shorter but no less important. The emphasis then lies on mapping the existing situation and determining the technical preconditions within which the new lighting system must operate.
What standards and certifications apply to both project types?
Both new terminal lighting and retrofit projects must comply with the same applicable standards. The applicable requirements are determined by the type of location, the activities that take place there, and any specific risks, such as the risk of explosion or extreme weather conditions. The EN 12464-2 standard for outdoor workplace lighting and the EN 13201 series for road lighting are commonly used reference frameworks for outdoor areas.
Maritime and offshore environments are subject to additional requirements regarding salt fog resistance, vibration stability, and corrosion resistance. Fixtures intended for these environments must have been demonstrably tested under those conditions.
Relevant certifications and standards for both project types include:
- IP rating (ingress protection) for dust and water resistance
- IK rating for impact resistance
- ATEX certification for hazardous areas
- CE marking as a basic requirement for the European market
- ISO 9001 for supplier quality assurance
- VCA certification for safe working during installation
An important point of attention is that during a retrofit, the new luminaires must comply with current standards, even if the rest of the installation is older. This means that a retrofit sometimes also requires adjustments to the existing installation to meet current requirements. In new construction, the entire system is designed in accordance with applicable standards from the start.
Case Study: DFDS Terminal Lighting in Vlaardingen
A concrete example of how the trade-off between retrofitting and new construction works out in practice is the project at DFDS Seaways in Vlaardingen. At this ro-ro terminal, the lighting needed to be replaced without interrupting daily loading and unloading operations — a classic operational constraint that applies to many terminals.
The technical challenge lay in the combination of factors: the existing masts were still structurally sound, but the luminaires no longer met the current lighting standards for workspaces and traffic routes. At the same time, the port environment placed high demands on the corrosion resistance and impact resistance of the new luminaires, due to the constant exposure to sea air and the intensive traffic on the quay.
The design choice fell on a targeted retrofit: the masts and cabling were retained, but the luminaires were completely replaced with high-quality LED solutions featuring the appropriate IP and IK ratings for the port environment. The installation was carried out in phases per site section, allowing the terminal to remain operational. An important lesson from this project is that a thorough preliminary measurement—including inspection of the mast bases and connection points—was essential to identify hidden defects early and prevent unexpected additional costs. This directly connects to the risk of hidden defects discussed earlier in this article. The complete project approach can be read on the DFDS Seaways Vlaardingen Project Page.
How JEL Products Helps with Terminal Lighting and Retrofit Projects
JEL Products guides organizations through the entire process—from the initial technical analysis through installation, commissioning, and maintenance. Whether it’s a completely new lighting project or a retrofit of an existing terminal, the approach is always based on a thorough engineering phase and proven technical quality.
What JEL Products specifically offers for this type of project:
- Design and production of luminaires in the Netherlands, tailored to the most demanding environmental requirements
- Complete peace of mind: from lighting calculation and mast design to foundation and installation
- ISO 9001 and VCA certified for quality and safety assurance
- Extensive experience with complex projects in ports, terminals, offshore, and heavy industry
- Guidance on subsidy and tax procedures related to the investment
Would you like to know which approach best fits your situation? Get in touch Contact JEL Products for a no-obligation technical consultation.