Case Study

Lighting Design & Installation .

Charter Dura-bar is a company that specializes in producing continuous cast iron bars and tubes using a proprietary casting process. Their products are used in a wide range of applications, including hydraulic cylinders, pump and valve components, and tooling. With a commitment to quality and innovation, Charter Dura-Bar has established itself as a trusted supplier in the metalworking industry.

The Problem.

Charter Dura-Bar is a 480,000 sq. ft. steel casting operation. Company leadership had set out to improve the environmental conditions of its facility for the employees and customers. A key component to that undertaking was lighting. Most of the lighting within the foundry had consisted of old mercury vapor and incandescent lighting. Very yellow. And most of the casting area was just too dark. Overall the facility was functioning on 200-400 lux. The goal was to double that output for the safety and wellbeing of the entire team, while improving quality for the customer.
> High heat environment posed a concern
We wanted to go with LEDs due to the energy saving opportunity. But the Wasmer team pointed out that you need to be careful when choosing LED lights for high heat environments. Others may talk about your 10-year savings with LEDs, but you won’t realize that savings if your lights only last a couple of years in those high heat environments. Nobody else pointed that out to us.
> Looking for a lighting partner – a real pro
We wanted somebody who could come in and tell us what we needed to do. Of all the suppliers we spoke with, only Wasmer dug-in to the depth we needed. They presented us with recommended lighting levels for tasks by area. They monitored temperatures in our high heat areas everyday for months via temperature logging devises. Not just at the surface, but up in the ceiling to know precisely what the environmental implications would be for the light fixtures. They installed test lights to make sure they would hold up to the conditions, before we purchased the balance of the lights.
> Needed to minimize facility interruption
We couldn’t really do the whole plant at one time. It would just be too disruptive. So, we broke the plant up into zones. We like to take care of projects like these during our scheduled summer and winter shutdowns. We lined up as much as we could get to for the summer shutdown, which included installing some test lights in the high heat area, so we could verify how they would hold up under real-world operating conditions.
Dura-Bar pre-installation image, lighting design case study
Dura-Bar Post Installation photo, lighting design and installation

The Solution.

Of all the companies we talked to, only Wasmer approached this lighting project from an engineering perspective, to help ensure we got the end result we wanted. With the data they gathered up front and the fact-based recommendations they came back to us with, we were confident we had the right solutions for our needs. This was especially true when it came to the options they presented us with for dealing with high heat environments.
> High heat can permanently damage LEDs
Once LEDs reach a certain heat threshold, they don’t perform as well. The damage is done. They’ll never be the same. But Wasmer discussed ways we could mitigate high heat challenges.
> Thermistors help prevent excessive heat
As internal temperatures within the fixture rise, thermistors power down the light to help prevent overheating. This protects LEDs against irreparable damage.
> Remote drivers significantly reduce internal heat build-up
Only Wasmer talked to us about using remotely located power supplies, or drivers, to minimize fixture heat loads. The drivers could be located in a cooler location, which is better for the life of the driver as well as the fixture.
> “Test lights” alone were a dramatic improvement
In our high heat areas, we installed four lights as a test to see how they would hold up to the heat. To see how thermistor trips might affect the lighting, we intentionally shut off two of the lights and ran only the remaining two. The resulting light was still better than what had in place previously.
It’s a real pleasure working with Wasmer. You rarely see such commitment and level of service anymore. Combine that with their technical expertise and the Wasmer team was just what we were looking for and needed on this project.

The Results.

Prevent excessive heat
using Thermistors

Reduced employee turnover
+ increase safety

light levels

What We Do.

We engineer lighting systems for every environment (high heat, high dust, corrosive vapors, etc) that reduce energy cost, maximize safety, increase employee morale, and increase productivity, resulting in a significant impact to your bottom line – all with turnkey project design and implementation.
What we do


Improving overall operating efficiency isn’t just good for you bottom line, it is good for the planet! Wasmer can help identify opportunities for your company to reduce emissions, while improving your production efficiency, employee productivity and reducing your carbon footprint. We engineer and implement a custom solution for your facility.

Building Partnerships.

When you entrust us with a key to your plant, we don’t take it lightly. Every step forward is taken with care, diligence, and a sharp mind. Thank you for the opportunity to build solutions, business, and friendships.