![Bilbao CSP Spain port night panorama]()
PORT · LOGISTICS · HEAVY DUTY
Spain Bilbao CSP International Port
Phase III Custom Lighting Solution
Quay / Gantry Crane / Container Yard Integrated Lighting System
A flagship port project in Central Europe delivered in three phases. CHZ provided DIALux professional optical simulation, multi-scenario customized luminaire combinations, port-specific electrical adaptation, and full on-site installation supervision — covering high-mast plazas, gantry cranes, and container yards with full environmental tolerance for salt-spray coastal conditions. A replicable customization blueprint for large European seaport retrofits.
01 / 10 Project Background
A flagship Central-European hub,
rebuilt for 24/7 heavy-duty throughput.
Bilbao is Spain’s third-largest seaport. COSCO Shipping CSP operates container, bulk, and oil berths with 45 million tonnes of annual throughput — and the legacy 2000W HID high-pressure sodium system had become the bottleneck: no standardized luminaire could match the port’s multi-zone, non-standard demands.
Why a turnkey customization was the only path
The Bilbao CSP concession handles containers, dry bulk, and oil products across multiple berths. Container and bulk-handling yards run around the clock, with peak shifts falling in the dark early-morning and late-evening windows. Reliable high-mast illumination is mission-critical for safety, throughput, and EU port compliance.
CHZ won the bid by combining three product series (FL08, FL21, FL32), DIALux-based optical simulation, and a coastal-grade electrical package — a turnkey customization no off-the-shelf vendor could match.
![Eight-head high-mast luminaire with CHZ floodlights lit at night]()
Phase II · Live deployment — 8-head high-mast plaza with CHZ floodlights lit at night.
02 / 10 Client Challenges
Five root causes forced a fully
customized port-lighting package.
A one-size-fits-all approach had already failed twice on this site. The operator needed a vendor who could engineer per-zone — not just ship a catalog SKU.
01
01
Multi-zone working conditions differ radically
3 zones
each with unique mounting height, throw distance, and corrosion class
High-mast yards, gantry-crane underbellies, and coastal quaysides each have unique mounting heights, throw distances, and corrosion requirements. Generic luminaires produced uneven illumination and large dark patches — a safety hazard for loading crews.
02
02
Legacy fixtures fail EU port standards
Old 2000W HID luminaires were energy-hungry and under-spec: average ground illuminance only 150 lx, uniformity 0.25, severe fog glare. Fell short of EU night-operation port requirements.
03
03
Unstable grid and frequent lightning
Wide voltage swings plus coastal thunderstorms meant standard drivers were undersized, surge protection was insufficient, and salt-spray corrosion caused repeated short-circuits. Maintenance cost stayed high.
04
04
No upfront optical design, on-site rework
Most vendors ship from stock with no 3D lighting simulation. Result: frequent post-installation re-aiming, schedule slippage, and unplanned construction cost.
05
05
Three-phase cross-compatibility mandate
The client expanded year over year and required that the brackets, electricals, and accessories stay identical across Phase I / II / III — enabling seamless, mix-and-match capacity expansion. Stock products could not satisfy unified compatibility.
03 / 10 Our Solution
Three series, one integrated package.
A coordinated floodlight family tailored to three distinct port zones — high-mast container yards, gantry-crane underbellies, and quayside service corridors. Common mounting interface, shared electrical architecture, and unified salt-spray coating across all three.
![CHZ-FL32 750W three-module LED floodlight]()
CHZ SERIES
FL32 · 750W
High-mast container yards (30m+)
Multi-module large floodlight for 30m+ ultra-high-mast plazas. 70,000 lm output, 30°–135° mixed optics, 180–528V high-voltage driver, 10kV surge protection.
![CHZ-FL21 450W four-module LED floodlight]()
CHZ SERIES
FL21 · 450W
Gantry cranes & mid-size yards
Mid-power modular floodlight for crane underbellies and yard partitions. 42,000 lm, 360° adjustable bracket, 100–528V wide-voltage driver, IP67 corrosion-resistant coating.
![CHZ-FL08 LED luminaire]()
CHZ SERIES
FL08 · 100–200W
Quayside corridors & service lanes
Compact floodlight for low-height quay areas, gates, and walkways. 50° / 90° / 120° wide-angle, IP66, 6kV surge protection. Lightweight housing does not occupy precious quay space.
04 / 10 Product Specifications
Port-grade modular floodlight family —
three series, one shared electrical DNA.
Detailed parameters for all three series shipped to Bilbao CSP. Each series carries a port-specific customization layer in addition to the baseline specification — coastal electrical, salt-spray coating, and a shared bracket system for cross-phase mix-and-match.
![CHZ-FL08 LED luminaire]()
FL08
A. FL08 — Compact Floodlight
Quayside corridors / Boarding areas / Service lanes
| Parameter |
Specification |
Port Customization Note |
| Power Range |
100W / 150W / 200W |
Three-step selectable for varied corridor widths |
| Luminous Flux |
13,000–26,000 lm |
~130 lm/W system efficacy |
| Color Temperature |
4000K / 5000K optional |
5000K chosen for quay visibility |
| Beam Angle |
50° / 90° / 120° |
Wide-angle default for low-mast coverage |
| Input Voltage |
AC 100–277V |
Wide-range driver, EU grid compatible |
| Surge Protection |
6kV line-line / 10kV line-ground |
Coastal-grade, lightning season-tested |
| IP Rating |
IP66 |
Salt-spray coating added for Bilbao quay |
| CRI |
Ra ≥ 70 |
Loading-crew visual recognition |
| Housing |
Die-cast aluminum, ADC12 |
Anti-corrosion prime + topcoat |
| Operating Temp |
−40°C to +55°C |
Bilbao coastal winter baseline |
| Lifetime |
L70 > 50,000h |
Driver replaceable for serviceability |
B. FL21 — Mid-Power Modular Floodlight
Gantry cranes / Mid-size yards / Service roads
| Parameter |
Specification |
Port Customization Note |
| Power Range |
300W / 400W / 450W |
Per-crane-head wattage matched to reach |
| Luminous Flux |
45,000–67,500 lm |
~150 lm/W system efficacy |
| Color Temperature |
5000K |
Cool-white for night-shift alertness |
| Beam Angle |
30° / 50° / 70° / 100°×150° rectangular |
Rectangular pattern for narrow under-crane aiming |
| Input Voltage |
AC 100–277V wide-range |
Critical for Bilbao grid swing 200–480V |
| Surge Protection |
10kV / 20kV optional |
20kV spec for gantry-crane underbelly |
| IP Rating |
IP66 |
Submersible 1m/30min, rain + spray safe |
| Bracket |
360° adjustable U-bracket |
On-site re-aiming without re-wiring |
| Wiring |
3m halogen-free cable, IP68 connector |
Plug-and-play replacement at the gantry |
| Weight |
7.2 kg (450W) |
Light enough for single-technician swap |
| Lifetime |
L70 > 50,000h |
Modular driver compartment for fast swap |
| Certifications |
CE / ENEC / RoHS |
EU port procurement compliant |
![Four-head high-mast configuration with CHZ FL21 modules]()
FL21
![CHZ-FL32 750W three-module LED floodlight]()
FL32
C. FL32 — High-Mast Heavy Floodlight
30m+ high-mast plazas / Container yards / Bulk-cargo zones
| Parameter |
Specification |
Port Customization Note |
| Power Range |
600W / 750W |
Per-head configuration for tiered throw |
| Luminous Flux |
90,000–112,500 lm |
~150 lm/W system efficacy |
| Color Temperature |
5000K |
Cool-white, container-reading visibility |
| Beam Angle |
30° / 50° / 70° / 90° / 135° |
Mixed layout for full yard, no dark corners |
| Input Voltage |
AC 180–277V |
High-voltage driver, EU industrial grid |
| Surge Protection |
10kV / 20kV |
20kV default for 30m+ mast exposure |
| IP Rating |
IP66 |
Dust-jet + heavy-spray safe |
| Module Count |
2 / 3 / 4 modules per housing |
Matched to pole height + coverage radius |
| Aiming |
Independent per module |
Each module aimed after DIALux sim |
| Weight |
15.5 kg (750W / 3-module) |
Stainless mounting hardware included |
| Operating Temp |
−40°C to +60°C |
Bilbao coastal summer baseline |
| Certifications |
CE / ENEC / RoHS / DIALux-verified |
IES files shipped per fixture |
05 / 10 Customization Highlights
Six customization layers behind
a single Bilbao CSP project.
What made Phase III different from a stock fixture roll-out — from per-zone optics to a DIALux-driven cross-phase standardization package.
01
Multi-scenario parameter differentiation
FL08 / FL21 / FL32 each customized for power, beam angle, surge protection, and voltage per zone — not the same SKU shipped three times.
02
DIALux parameter-based simulation
Full photometric and flux data imported into DIALux to optimize layout before installation. Different from vendors that only sell standard products off the shelf.
03
Coastal electrical engineering
Wide-voltage driver, tiered surge protection, and salt-spray coating — a three-pronged package targeting the harshest coastal-port failure modes.
04
Cross-phase product standardization
Phase I / II / III fixtures share identical brackets, electricals, and mounting accessories. Supports long-term phased expansion and iterative upgrades.
05
On-site engineering supervision
CHZ safety officer on site at Bilbao across Phase II and Phase III commissioning — final aiming verified, IES data handed to client engineering team.
06
Full IES-file optical documentation
Complete IES files and photometric curves delivered with each fixture, enabling the client’s engineering team to run their own DIALux simulations for any future yard expansion.
06 / 10 On-Site Project Scenes
Captured during the Phase II & III
commissioning visits.
Real deployment photos from Bilbao CSP — not renders. Each frame is a moment from the actual on-site commissioning walk-through.
![CHZ safety officer in front of CSP Spain gantry crane]()
PHASE II · GANTRY
CHZ engineer on site at CSP Bilbao, in front of a Phase II gantry crane fitted with FL21 450W modules.
![Container yard at night with high-mast CHZ floodlights]()
PHASE III · YARD
Phase III high-mast container yard lit by FL32 750W modules. CMA CGM boxes clearly readable from 30+ meters away.
![Eight-head CHZ high-mast floodlight top view]()
PHASE III · TOP-DOWN Eight-head CHZ high-mast configuration, top-down view. Each FL32 module is independently aimed for full yard coverage with no dark zones.
07 / 10 Quantified Results
Before & after — hard numbers
from the post-commissioning report.
The legacy 2000W HID system was replaced with an FL21 / FL32 mixed configuration. Five measured metrics, four headline KPIs.
| Metric |
Legacy 2000W HID |
CHZ FL21 / FL32 Mix |
Improvement |
| Per-Point Power |
2000W |
450W / 750W |
−60% to −77% |
| Yard Avg Illuminance |
150 lx |
230 lx |
+53% |
| Uniformity (Uo) |
0.25 |
0.43 |
+72% |
| Annual Failure Rate |
High (driver / salt-fog related) |
Low (modular swap) |
−75% |
| EU Port Compliance |
Below spec |
Exceeds spec |
Pass |
POWER
−60%
Per-point power drop vs. 2000W HID baseline
LIGHT
+53%
Yard avg illuminance gain, 150 → 230 lx
UNIFORM
+72%
Uniformity Uo improvement, 0.25 → 0.43
UPTIME
−75%
Annual failure rate cut, modular swap enabled
08 / 10 Customization Service Highlights
Why Bilbao CSP chose CHZ as a long-term
partner for phased port expansion.
Four service capabilities that go beyond the luminaire itself — the part of the engagement that keeps a port operator coming back for the next phase.
01
Multi-model parameter differentiation
FL08 / FL21 / FL32 each customized for power, beam angle, surge protection, and voltage per zone. Adapts to complex port working conditions rather than forcing a single product onto every area.
02
Parameter-based optical simulation
Full photometric and flux data imported into DIALux to optimize layout before installation. Different from vendors that only sell standard products off the shelf.
03
Coastal electrical engineering
Wide-voltage driver, tiered surge protection, and salt-spray coating — a three-pronged customization targeting the harshest coastal port pain points.
04
Cross-phase product standardization
Phase I / II / III fixtures share identical brackets, electricals, and mounting accessories. Supports long-term phased expansion and iterative upgrades.
“
A replicable customization blueprint for large European seaport retrofits — and a long-term partner for phased port capacity expansion.
The Bilbao CSP Phase III project is a benchmark customization case for large European seaports. The FL08 / FL21 / FL32 parameterized customization package can be directly replicated at global container ports, bulk-cargo terminals, and port-adjacent logistics parks.
CHZ can adjust luminaire power, beam angle, and electrical parameters to suit any combination of pole height, grid condition, and lightning environment — delivering a complete industrial-lighting solution that covers optical simulation, product customization, batch delivery, and on-site engineering supervision from a single supplier.
Plan a similar port-grade lighting project?
Send us your pole height, grid voltage, and salt-spray class. We’ll return a DIALux simulation, a per-zone luminaire spec, and a fixed quotation within 5 working days.
Start a Customization Brief →
