As a manufacturer of lighting solutions for demanding environments and as a crucial part of our commitment to sustainability, we have set ourselves the goal of designing and producing products that have a service life of over 30 years. Read on to find out about our materials and the rigorous testing at Designplan that ensures our excellent Design Life.
Material Selection and Product Longevity
Our commitment to quality is reflected in our choice of materials, ensuring a product lifespan exceeding 30 years. We use premium grade aluminium alloy for our die castings and 6063 alloy for our extrusions. Zintec coated sheet steel is the standard for our fabricated steel products, which feature fully seam welded external joints for enhanced durability.
Impact Resistance and Ratings
Designplan products are engineered to withstand significant impact, boasting high IK and IP ratings. These ratings are crucial indicators of a product’s ability to resist environmental factors such as water ingress and mechanical impacts.
Maintenance and Upgradability
A key aspect of our design philosophy is the ease of maintenance and the capability for upgrades throughout the product’s life, ensuring that our solutions remain at the forefront of technology and functionality.
Designplan products are sustainably designed to cut energy use by 50–60%, reduce maintenance with long-lasting LED gear trays, and minimise disruption with quick, easy installation. They improve safety, save money with a 2–4 year ROI, and future-proof your lighting for up to 30 years.
Our retrofit brochure details the benefits of retrofitting and the standards that need to be met.
Salt Spray Testing
To assess the endurance of our paint finishes, we employ an accelerated corrosion test. Products undergo a rigorous salt spray test, where a saline solution is atomised onto cross scribed surfaces. This process intensively simulates prolonged exposure to corrosion, with our finishes demonstrating resilience for over a thousand hours under these harsh conditions.
IP and IK Testing Standards
Our products adhere to the international standards IEC 60529-1:2003 for IP ratings and IEC 62262:2002 along with IEC 60068-2-75:2014 for IK ratings. These standards measure a product’s resistance to particulate and water ingress (IP) and its capacity to withstand mechanical impacts (IK).
IP Testing Standards
The Ingress Protection (IP) rating system is a crucial standard for determining the protective qualities of enclosures around electronic equipment. The first digit of the IP rating signifies the level of protection against solid objects and particulates, ranging from no protection to complete protection against dust. The second digit indicates the level of protection against water, starting from no protection to protection against the effects of immersion.
IK Testing Standards
Designplan’s commitment to high IK ratings reflects the company’s dedication to producing durable and reliable products. However, the realisation that an IK11 rating does not suffice for the demanding environments where their products are installed led to further testing. By extrapolating the EN60068-2-75 standard, Designplan has been able to extend the impact resistance of their products up to an impressive IK20 rating, equivalent to withstanding 250 joules of impact. This requires the development of bespoke testing equipment, which is set up in our in-house laboratory.
Thermal Resilience
Manufacturing Long Lasting Luminaire Bodies
The manufacturing methods for luminaire bodies at Designplan include casting, extrusion, and fabrication. Cast and extruded bodies are made from various grades of aluminium, such as LM6 aluminium alloy for our die castings and 6063 alloy for our extrusions, known for its corrosion resistance. This inherent quality, combined with additional pre-treatments and powder coating, ensures that the products can withstand harsh internal and external environments.
Fabricated bodies, on the other hand, are typically constructed from Zintec, a zinc-coated steel that offers superior rust and corrosion protection compared to uncoated mild steel. The application of powder coating on Zintec further enhances its durability, making it an excellent choice for both indoor and outdoor applications. Designplan’s meticulous approach to material selection and product testing underscores our commitment to delivering high-quality, robust lighting solutions.
Manufacturing High Corrosion Resistance Luminaires
The process of manufacturing high corrosion resistance luminaires involves a meticulous pre-treatment and coating procedure to ensure the longevity and durability of the product. For extreme environments we also use 316L stainless steel, known for its superior corrosion resistance, which is a strategic choice for environments with harsh conditions.
The pre-treatment process is a multi-stage affair:
Zinc Phosphate Surface Conversion
This initial stage applies a zinc phosphate layer that serves two purposes: it acts as a corrosion inhibitor and enhances the adhesion of the powder coating.
Town Water Rinse
A thorough rinse with town water removes residues from the initial treatment.
Demineralised Water Rinse
The use of in-house processed demineralised water ensures the removal of any lingering impurities, setting the stage for a clean coating application.
Chromium-Free Conversion Treatment
This final pre-treatment step provides an additional layer of protection to the base material and further improves powder adhesion.
Following pre-treatment, the drying oven plays a crucial role in preparing the product for coating by removing all moisture.
The Powder Coating Process
The electro-static powder coating process utilizes industry-leading materials and equipment, such as Sherwin-Williams powder and Gema spraying equipment, to achieve a consistent and even application. The recommended polyester powder is suitable for both indoor and outdoor settings, complying with the standards of BS6496/7.
The curing oven is the last step where the applied powder is transformed into a durable and protective coating, ensuring the product withstands the test of time and environment. This comprehensive approach to coating fabricated luminaires not only meets industry standards but also provides a robust solution for products exposed to demanding environmental conditions.
We offer a number of corrosion resistant powder coat paint options for our luminaires.
Products
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