Background
A critical section of Interstate 95 suffered severe pavement damage requiring immediate overnight repair. The work zone spanned approximately 800 m² (8,650 ft²) and was located in a remote area without access to mains electricity. With daytime traffic volumes exceeding 50,000 vehicles, all repair work had to be conducted at night between 10:00 PM and 5:00 AM.
The department needed a lighting solution that could be deployed rapidly, operate on battery power, provide wide-area illumination without glare for passing motorists, and withstand unpredictable weather conditions.
The Challenge
| Challenge | Details |
|---|---|
| No grid power | Remote location with no access to mains electricity |
| Rapid deployment | Crew had only 30 minutes of setup time before work window began |
| Worker & traffic safety | High-speed highway (65 mph) required glare-free lighting to avoid blinding drivers |
| Weather exposure | Forecast included wind gusts and potential rain |
| Limited crew | Only two workers available for equipment setup |
The Solution
The department deployed a Columus™ XN400 Inflatable Light Tower—a battery-powered portable lighting system designed for emergency and construction applications-44.
Key specifications of the XN400 model:
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Light source: 4 × 100W HID Xenon lamps, delivering 40,000 lumens maximum output-
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Power: DC 12V/24V battery operation (lead-acid battery pack, 24V-200Ah)-
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Warm-up time: < 30 seconds-
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Restrike: Instant-
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Color temperature: 4200K neutral white-
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Coverage: 4,071 m² (43,803 ft²) at >1 lux-
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Wind resistance: Up to 60 km/h-
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Protection rating: IP44 (rain and dust proof)-
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Setup time: One person, under 2 minutes-
Deployment
A single crew member carried the Columus XN400 from the truck to the worksite center and connected it to the 24V-200Ah battery pack. The built-in blower inflated the column within seconds, raising the 360° diffused light canopy to a height of 4 meters-. The entire setup—from unpacking to full illumination—was completed in under 2 minutes-44.
The glare-free lighting fixture provided uniform, shadow-minimized illumination across the entire 800 m² work zone, allowing paving crews to work safely and efficiently-.
Results
| Metric | Result |
|---|---|
| Setup time | < 2 minutes (vs. 25–30 minutes for conventional tower) |
| Battery runtime | 8+ hours (24V-200Ah) — covered entire 7-hour work window- |
| Worker productivity | 30% increase in night shift output due to superior lighting quality |
| Safety incidents | Zero near-misses or driver complaints regarding glare |
| Weather resilience | Withstood 45 km/h wind gusts and light rain without issue |
Key Outcomes
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Time Saved: The rapid deployment saved approximately 25 minutes per night compared to conventional metal halide towers, translating to over 3 hours of additional productive work time across the 7-night project.
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Battery-Powered Operation: The DC power system eliminated the need for a noisy generator at the worksite, reducing noise pollution and allowing crew members to communicate clearly without hearing protection—a critical safety advantage in a highway environment-.
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Enhanced Safety: The 360° glare-free diffused illumination eliminated blinding hotspots that typically affect oncoming traffic, significantly reducing the risk of secondary accidents-.
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Weather-Proof Performance: The IP44-rated fabric enclosure protected the lighting system from rain and dust throughout the project, while the 60 km/h wind resistance ensured stable operation even during adverse conditions-.
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One-Person Operation: With only two crew members available for setup, the Columus XN400's single-person deployment capability proved invaluable, freeing the second worker to focus on other preparatory tasks.
Client Testimonial
"The Columus XN400 transformed our nighttime highway repair operations. In under two minutes, we had 40,000 lumens of clean, shadow-free light covering our entire work zone—no generator noise, no glare for passing traffic, and it ran all night on a single battery charge. This is the future of portable worksite lighting."