Telescopic Mast Systems

Pneumatic & Hydraulic Telescopic Masts

Outside Front Cover

Abacus Lighting - Pneumatic and Hydraulic Telescopic High Masts At Abacus Lighting, we specialise in the design, manufacturing, installation, maintenance, and repair of high-quality pneumatic and hydraulic telescopic masts. Our expertise developed over 65 years in the lighting industry, ensures that every mast meets the highest standards of safety, durability, efficiency, and performance. Whether you need a custom-built solution or routine servicing, our team is equipped to support your needs from start to finish.

Phone: 01623 511 111 - Email: info@abacuslighting.com - Website: abacuslighting.com

Pneumatic & Hydraulic Telescopic Masts

Contents:

Inside Front Cover

Phone: 01623 511 111 - Email: info@abacuslighting.com - Website: abacuslighting.com

Pneumatic & Hydraulic Telescopic Masts

Design & Manufacturing: Precision Engineering - We employ advanced manufacturing techniques to produce world-leading pneumatic and hydraulic telescopic masts that offer superior strength, reliability and to bespoke designs that only a handful of manufacturers around the world can achieve.

Custom Solutions - Our engineering team collaborates closely with clients to design telescopic masts and lighting solutions tailored to specific requirements, ensuring optimal performance for various applications globally.

Lighting Design - Abacus’s lighting design engineers create the ideal lighting solution to meet safety and security needs or comply with the latest UHD broadcasting standards, suitable for any environment.

Innovative Technology - We integrate the latest advancements in telescopic mast and LED technology with generations of design and manufacturing expertise, providing efficient and robust lighting solutions.

Installation: Professional Setup - Our fully trained installation engineers ensure that every telescopic lighting project is installed to the highest safety and performance standards.

Site-Specific Adaptation - We customise the installation process to accommodate different environments and operational needs. Our experienced installation team has successfully completed numerous prestigious turn-key projects around the globe, including Lord’s Cricket Ground, Kensington Oval, and Kempton Park Racecourse, to name a few.

Maintenance & Repairs: Routine Servicing and Repairs - Regular maintenance ensures the longevity and reliable performance of our telescopic masts and lighting solutions. Our technicians are skilled in diagnosing and repairing luminaires, drivers, head-frames, and pneumatic and hydraulic telescopic mast systems, minimising downtime efficiently.

Spare Parts & Upgrades - We provide a comprehensive range of spare parts and upgrade services to enhance the performance of existing mast and luminaire installations.

Phone: 01623 511 111 - Email: info@abacuslighting.com - Website: abacuslighting.com

Pneumatic & Hydraulic Telescopic Masts - Making The Right Choice Telescopic Pneumatic & Hydraulic Lighting Masts When choosing between a pneumatic and a hydraulic lighting mast, it’s essential to consider your specific needs regarding operational capabilities, the required lighting solution, and future maintenance.

This guide on pneumatic and hydraulic telescopic masts will assist you in exploring the options and services available from Abacus Lighting, enabling you to make an informed decision for your project.

Pneumatic Telescopic Masts - Application Criteria: A pneumatic telescopic mast is the ideal choice if you need a lightweight, quick-deploy solution with a small headframe (under 25m high) and low maintenance.

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Hydraulic Telescopic High Masts - Application Criteria: Opt for a hydraulic telescopic mast if your focus is on supporting heavy equipment, utilising a large multi-luminaire head-frame, achieving heights over 30 meters, ensuring durability, and operating smoothly even in extreme conditions.

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Phone: 01623 511 111 - Email: info@abacuslighting.com - Website: abacuslighting.com

Pneumatic Telescopic Masts

Pneumatic vs. Hydraulic Lighting Masts Advantages: 1. Lightweight & Portable - Pneumatic masts are typically made from aluminium, making them lighter and easier to transport and install.

2. Rapid Deployment - These systems can extend quickly using compressed air, ensuring fast setup times in critical situations.

3. Low Maintenance - With fewer mechanical components, pneumatic masts require less maintenance compared to hydraulic alternatives.

4. Smooth Operation - The air-powered mechanism allows for smooth and controlled extension and retraction of the mast.

5. Cost-Effective - Generally, pneumatic systems are more affordable than hydraulic systems, both in terms of initial investment and ongoing maintenance.

6. Flexibility - A wide range of telescopic options is available with pneumatic masts, often resulting in shorter lead times.

Disadvantages: 1. Air Supply Requirement - Pneumatic masts require a reliable air compressor for operation, which can incur additional costs.

2. Lower Load Capacity - Compared to hydraulic systems, pneumatic masts have a reduced weight- bearing capacity, limiting the types of lighting or equipment they can support.

3. Environmental Sensitivity - Extreme weather conditions, such as high humidity or freezing temperatures, can negatively affect pneumatic performance.

4. Design Limitations - While there is a comprehensive range of options available for various applications, the design may be limited by the telescopic options offered.

Phone: 01623 511 111 - Email: info@abacuslighting.com - Website: abacuslighting.com

Pneumatic Telescopic Masts Telescopic Pneumatic Masts - Product Overview The Telescopic Pneumatic Mast range is ideal for various lighting applications where full-height permanent masts are not practical or necessary. With innovative and user-friendly engineering solutions, our masts are both flexible and practical, allowing them to more than double in height from their retracted position.

These pneumatic masts are operated using compressed air and can be raised or lowered either remotely or manually from the base of each mast.

Designed for seamless operation, these systems feature automatic controls for precise performance. An external enclosure houses all the key components, ensuring easy access for maintenance and optimal protection of the internal mechanisms.

Key Telescopic Pneumatic Masts Range Extended Height (m)

Retracted Height (m)

Number of sections

Base Diameter (mm)

Top Shaft Diameter (mm)

Maximum Head-load (kg)

12.7

2.5

7

284

130

280

14.1

2.7

7

284

130

280

14.8

2.8

7

284

130

280

15.5

2.9

7

284

130

280

16.2

3.0

7

284

130

280

16.9

3.1

7

284

130

280

17.6

3.2

7

284

130

280

18.3*

3.3

7

284

130

280

19.7*

3.2

8

284

110

200

20.5*

3.3

8

284

110

200

*Contact Abacus Lighting for our full, comprehensive range of pneumatic masts

Telescopic Pneumatic Masts - Key Features • Ranging from 5m - 25m • Pneumatic Telescopic Masts are operated using compressed air • Anodised aluminium finish • Option for internal multi-core cable available on request • Anemometer controlled retraction if the design wind speed is exceeded • Lowers to more than half the operating height, minimising any visual intrusion • Designed to work in a tubular format • Accessible control features from base section

Phone: 01623 511 111 - Email: info@abacuslighting.com - Website: abacuslighting.com

Pneumatic Telescopic Masts Pneumatic Telescopic Lighting Masts - How Do They Work: Pneumatic telescopic lighting masts operate using compressed air to extend and retract multiple telescoping sections, allowing for adjustable height and positioning of mounted lighting equipment:

1. Structure & Components • Telescopic Sections: Multiple cylindrical sections nested within each other • Air Compressor or Pump: Supplies compressed air to extend the mast • Control Valves: Regulate air pressure for smooth extension and retraction • Seals & Locking Mechanism: Ensures stability and prevents air leaks • Mounted Equipment: Typically high-powered LED or halogen lights

2. Operation • Extension: Compressed air is introduced into the mast, pushing the sections upward sequentially • Locking Mechanism: Some masts have mechanical or pneumatic locks to maintain height • Retraction: Releasing air pressure allows gravity or internal springs to collapse the sections back down

3. Power Source & Control • Electric compressor, or vehicle air system extends the telescopic mast • Controlled via switches, remote control, or automated systems can be used to extend and retract the masts

4. Applications • Emergency & rescue services (Usually mobile pneumatic masts) • Construction sites (Usually mobile pneumatic masts) • Military & defence operations (Fixed or mobile pneumatic masts) • Sports and entertainment broadcasting (Fixed or mobile pneumatic masts)

Phone: 01623 511 111 - Email: info@abacuslighting.com - Website: abacuslighting.com

Hydraulic Telescopic Masts Hydraulic vs. Pneumatic Lighting Masts Advantages: 1. Higher Load Capacity - Hydraulic systems can support heavier lighting fixtures, additional equipment and higher heights can be reached making them ideal for demanding applications.

2. Strong and Durable - Designed for heavy-duty use, these masts offer increased stability and longevity, even in harsh conditions.

3. Precise Control - Hydraulic mechanisms allow for controlled extension and retraction, reducing the risk of damage during deployment.

4. Operates in Extreme Conditions - Unlike pneumatic systems, hydraulic masts are less affected by environmental factors such as temperature fluctuations, this ensures worldwide suitability.

Head-frame Assembly

5. Flexibility - Abacus Lighting’s hydraulic telescopic high masts are custom-manufactured in our purpose built manufacturing plant in the UK. This specialised manufacturing capability allows Abacus to lead the way in tailored lighting solutions and telescopic mast design, where competitors cannot match our expertise.

Disadvantages: 1. Heavier and Less Portable - Due to their robust construction and additional components, hydraulic masts tend to be heavier and require more effort to transport.

2. Higher Maintenance - Hydraulic systems require regular maintenance checks and fluid replacement to ensure optimal performance.

3. Slower Deployment - While offering precise control, hydraulic masts generally take longer to fully extend compared to pneumatic alternatives.

Telescopic Assembly

4. Higher Cost - The increased durability and load capacity come at a higher initial and maintenance cost.

External Cable Covers

Base Compartment

Mast Shown In Retracted Position

Mast Shown In Extended Position

Phone: 01623 511 111 - Email: info@abacuslighting.com - Website: abacuslighting.com

Hydraulic Telescopic Masts Telescopic Top Section Key-ways ensure directional stability during the processes of extending and retracting

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Telescopic Base Section

Hydraulic Telescopic Lighting Masts - How Do They Work: Hydraulic Telescopic Lighting High Masts use a combination of hydraulic rams, chains, and cable protection to extend and retract efficiently.

1. Hydraulic Ram Mechanism (Lifting & Lowering) • The high mast consists of multiple telescoping sections nested inside one another • A hydraulic ram (or cylinder) is positioned at the base of the mast • When hydraulic fluid is pumped into the cylinder, it extends the ram, pushing the inner sections of the mast upwards, thereby raising the lighting system • To retract, the hydraulic system reverses, and the fluid is released, allowing the sections to slide back down under their weight or assisted by controlled pressure

2. Chain System (Controlled Extension & Retraction) • Heavy-duty chains are attached to the mast sections and guided through a pulley system • he hydraulic ram extends, the chains help in synchronising the movement of each section, ensuring they rise evenly • When retracting, the chains guide the sections back down in a controlled manner, preventing free-fall or misalignment

3. Cable Protection System (Managing Electrical Cables & Safety) • Since lighting systems require electrical connections, a cable protection system is integrated to prevent tangling, damage, or over-stretching of power cables • This typically includes a cable drum, flexible conduits, or internal cable carriers that move in sync with the mast’s extension and retraction

Safety Features & Considerations • Limit switches - to prevent overextension or over-retraction • Hydraulic pressure control - to ensure smooth operation and avoid sudden jerks • Locking mechanisms - to secure the mast in place when fully extended

4. Typical Applications Sports & Recreational Facilities • Stadiums, sports complexes, race tracks, entertainment arenas and golf courses

Phone: 01623 511 111 - Email: info@abacuslighting.com - Website: abacuslighting.com

Hydraulic Telescopic Masts Bespoke Manufactured Multi-Luminaire Head-frames: Abacus Lighting custom-manufactures lighting head-frames tailored to your exact requirements. Our in-house lighting design engineers ensure each solution meets today’s safety standards and UHD broadcasting needs. With over 65 years of experience in the lighting industry, we bring expertise and innovation to every project Abacus Lighting provides bespoke head-frame lighting solutions, offering design, manufacturing, installation, and maintenance as part of a full turnkey service. Our lighting systems can be remotely or centrally controlled using standard equipment for seamless operation.

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Phone: 01623 511 111 - Email: info@abacuslighting.com - Website: abacuslighting.com

Pneumatic & Hydraulic Telescopic Masts

Inside Back Cover

Phone: 01623 511 111 - Email: info@abacuslighting.com - Website: abacuslighting.com

Pneumatic & Hydraulic Telescopic Masts

Outer Back Cover

Phone: 01623 511 111 - Email: info@abacuslighting.com - Website: abacuslighting.com