Method Statement for Installation of Inset Light Fitting

1.

Upon receipt of goods at the site store, check all packages for visible damage. Every
damaged box should be opened and its content inspected for damage.

2.

Store the light assembly preferably in its original packing in a protected area. When
stored unpacked, please take care not to damage the cable insulation.

3.

Unpack the light assembly at the installation site to avoid damage during
transportation and handling.

4.

Safety precautions
Operating and maintenance personnel should refer to ICAO Airport Services Manual
Part 9, Airport Maintenance Practices and to FAA Advisory Circular AC 150/534026 "Maintenance of Airport Visual Aid Facilities" for instructions on safety
precautions. Personnel must always observe the safety regulations. The
equipment has been designed and manufactured to allow safe and secure operation,
however, the following rules must be strictly observed.

5.

Installation

5.1

Installation tools and materials

Alignment device
Core drilling machine with diamond blades
Torque wrench, socket 17mm
Two component fixing compound - Dobefil-60 + Hardener 758( Dr. Beck)
Diesel Generator Set
Water drums

5.2 Specifying the location

The applicable documents for location details and tolerances are the following:
ICAO

Annex 14
Aerodrome Design Manual Part 4

FAA

Advisory Circular AC no. 150/5345-46a

The location of the lights should also be crosschecked by a qualified surveyor to

ensure that the lights are aligned correctly.
5.3 Installation
The outer diameter of base receptacle is 218 mm and the height is 120 mm
The location of a inset light is drawn by using a centre point and plywood plate,
230 mm and on Runway lights are 60cm offset from Centreline of Runway and on
Taxiway 30cm offset from Taxiway C/L.
5.3.1 Coring of a hole for inset light

A hole, 230 mm, depth 120 mm, is drilled with a core drilling machine to the
pavement. Asphalt is removed from the hole by breaking the surface with a shaking
hammer.
The bottom of the hole is smoothed. The hole is cleaned and dried well with
compressed air and if hole is still wet, use lime.
The Shallow base is sealed into the recess cored out in the pavement and the
isolating transformer is installed in a steel base or pit located in or next to the runway
shoulder.
The light fixture is connected to the transformer by means of a two-core cable
running into conduits in the sub grade or the lower layers of the pavement.

5.3.2 Fixing of a base receptacle, aiming

Make sure that the hole is clean and completely dry. The outer surface of the base receptacle is
cleaned and dried.
Alignment device is fixed to the base receptacle in such a way that the aiming
grooves of the alignment device is parallel to the grooves in the base receptacle.
Make sure that the scale shows zero toe-in.

Secondary cable is drawn through the hole in the base receptacle so that about 30
cm of cable is inside the base. Clamp screw is lightly tightened so that it can be opened
by hand.
When plastic protection tube is used, the cable can be drawn into the base receptacle
after fixing the base. The plastic tube is screwed in from the outside of the base
receptacle.
Suitable amount of two component fixing compound is mixed according to the instructions of the
manufacturer. The amount needed depends on the diameter and depth of the hole. We
will be using:
Dobefil 60
A Room temperature curing filled epoxy-casting system with Hardener 758
Product Description
Dobefil 60 is a filled, solvent less epoxy compound. Specially formulated and processed
to obtain void free casting, potting encapsulated components. It contains specially
selected and processed fillers, which are incorporated under vacuum mixing. It is
ready to use filled epoxy system having low viscosity at processing temperature. Dobefil
60+ Hardener 758 is a fast curing system with a hard cured mass.
Hardeness 758 is a low viscosity polyamine liquid hardener. The curing of Dobefil 60 +
Hardener 758 takes place by polyaddition reaction, which occurs at room temperature.
The cured mass of Dobefil 60+ Hardener 758 shows good mechanical, electrical &
chemical properties. Because of presence of filler in Dobefil 60, the cured
mass
shows reduced shrinkage, low coefficient of thermal expansion & increased thermal
conductivity. The combination of Dobefil 60 + Hardener 758 is used in electrical
components of thermal class 120(class E)

Processing Methods
Dobefil 60contains fillers, which have tendency to settle on long storage. Dobefil
60, should therefore, be stirred to a homogenous mixture, each time it is drawn from the
container. Hardener 758 should be mixed in Dobefil 60 compound at room temperature &
the mixture should be used within the specified pot life.
Properties of Components as supplied

Type of Compound

Dobefil 60 [+]

Hardener 758

Filled epoxy

Polyamine

Off White filled resin

Pale yellow clear

pale brown

Colour & Appearance [*]

DBI 1001[**]

Density at 250C [*]

DBI 3074 [**]

g/ml

1.50 - 1.60

0.975 (Typical)

Viscos ity at 300C [*]

DIN 10 mm Cup

DBI 1015A [**]

30 - 40

Viscosity at 250C by
Brookfield [*]

DBI 3005

mPas.

Flash Point (Open cup)

DIN 51584

0C

>100

>100

Ash Content [*]

DBI 1017

46 - 50

Amine value[*]

DBI 1012[**]

1290-1410

Storage stability

In original sealed
container at R.T.

months

12

12

15-35

Recommended Curing Schedule

For all epoxy systems the hardeners are required to be mixed n Dobefil 60 compound at
room temperature and the mixture used within the specified pot life.
Hardener 758 has fast reactivity at room temperature, especially at ambient
temperature above 30C. Small mixture quantity of generally less than 1 kg should
therefore be prepared at a time
Always check validity date of resin before using it. The use of resin beyond its validity
date may lead to defective or unreliable sealing.
An even amount of fixing compound is spread on the bottom and sides of the hole.
The installation and alignment device still attached to the base receptacle, they are
fitted into the hole so that the fixing points of the alignment device will settle well onto
the pavement and the base receptacle will not swing.
Aim the base with respect to the centre line markings so that the aiming grooves are
parallel to the centerline.

Alignment device can be unfastened after the base receptacle fixing compound is
hardened. Surplus fixing compound is removed and sides are smoothed. In front of
light gaps asphalt must be removed so that no threshold exists.
Pull up the supply cable and plug the light fitting cable into the socket. Apply insulating
tape around the plug/ socket assembly.
5.3.3 Fixing of a top cover
Place the o-ring gasket between the base receptacle and top cover. The secondary
plug and receptacle are connected inside the base receptacle.
Make sure that the cable will settle properly inside the base receptacle. The top
cover is aligned with respect to the groove in the base receptacle, which has been set
to the desired direction. The top cover is fixed with two bolts.
First fasten the bolts by hand. By using a torque wrench fasten the bolts gradually in a
sequence to a torque of 40 Nm.