Project Overview
Abacus Lighting is proud to support Northampton Saints Rugby Club with essential lighting maintenance at their home ground, the Cinch Stadium at Franklin’s Gardens. This project focused on ensuring the continued reliability and performance of both the pitch floodlighting system and the stadium roof-mounted luminaires. The work was particularly time-sensitive and required close coordination with the club, as it took place during team training sessions in preparation for a major European Cup final. The lighting infrastructure at the stadium includes four GL620 40m base-hinged masts, each equipped with CH3 metal halide floodlights, and additional CH1 metal halide units fixed to the stadium roof structure.
Protect your investment with Abacus’ scheduled maintenance plans
Neglecting routine maintenance can have serious implications for the warranty of an LED lighting solution. Most manufacturers stipulate in their warranty terms that proper installation and ongoing maintenance are required conditions for coverage. If a failure occurs due to issues that would have been identified during a scheduled maintenance check – such as dirt build-up causing overheating, loose connections, or water ingress – warranty claims may be denied.
This could result in costly repairs or replacements that would otherwise have been covered. Therefore, maintaining a documented schedule of inspections and servicing not only extends the life and efficiency of the lighting system but also protects the investment by ensuring continued warranty support.
Maintenance of GL620 High Masts
The Abacus team began by lowering each of the GL620 masts, using our signature base-hinged mechanism, which allows safe and efficient ground-level access to the floodlights.
Key maintenance activities included:
• Replacing failed lamps in the CH3 floodlight units
• Testing all electrical connections
• Mechanical inspections of each fitting and support structure
• Full mast condition assessment to ensure safe re-raising
• Completing any necessary repairs before each mast was
returned to its upright position
After maintenance, the stadium floodlights were left on for an extended period to ensure all CH3 units were operating at full performance.
This case study features data sheets for the Challenger 1 and Challenger 3 LED upgrades using advanced LED technology. These upgrades reduce energy costs, provide instant lighting, and require minimal maintenance. They also have a longer lifespan than traditional metal halide lights. Contact Abacus for more information on our LED upgrades.
Stadium roof-mounted lighting maintenance
To service the CH1 metal halide units on the stadium roof, the team utilised a Mobile Elevating Work Platform (MEWP) to safely access each luminaire.
Every CH1 unit underwent a thorough electrical and mechanical inspection, including:
• Accessing the Stadium lights via a (Mobile Elevating Work Platform) MEWP
• Checking terminal and lamp compartments individually
• Testing and fault-finding
• Performing on-the-spot repairs to restore performance
Challenges and coordination
One of the key challenges of this project was working at height with heavy lighting equipment, while ensuring minimal disruption to team activities. The Abacus Maintenance Team worked closely with Northampton Saints’ ground staff to coordinate timings so that critical maintenance could proceed without interfering with the team’s training on the pitch.
Project conclusion
All four GL620 masts and stadium roof lights were fully inspected, serviced, and restored to optimal working condition. This proactive maintenance ensured the Saints’ floodlighting was reliable and performance ready for evening matches and high-profile events. Abacus Lighting’s commitment to safe, efficient, and high-quality lighting maintenance, especially in operational environments, makes us the trusted choice for sports facilities around the world. Whether for routine servicing or urgent repairs, our team brings the technical expertise and coordination required to keep lighting infrastructure running brilliantly.
