CU Phosco In-Tension Raise & Lower High Mast System
The challenge
Maintaining high mast lighting - often reaching up to 60 metres - has traditionally involved significant safety risks and operational challenges. Conventional systems typically require technicians to work at height or rely on latch-based raise-and-lower mechanisms. However, these latches are prone to jamming due to environmental contaminants like dirt, bird droppings, salt, and dust. When this happens, maintenance teams must deploy costly high-access equipment to manually dislodge the stuck carriage, increasing downtime and exposing workers to elevated safety risks.
This not only disrupts operations in critical environments such as ports and airports but also drives up maintenance costs and reduces system reliability. CU Phosco recognised the need for a safer, more efficient solution that eliminates the need for elevated work altogether.
The innovation
CU Phosco’s In-Tension Raise & Lower High Mast System is a breakthrough in high mast lighting technology. It replaces traditional latch mechanisms with a patented in-tension wire rope system, allowing all maintenance to be carried out safely at ground level.
The system uses stainless steel wire ropes held in constant tension to support the luminaire carriage. With no latches to jam, the carriage can be raised and lowered smoothly and reliably, regardless of environmental conditions. A patented in-tension winch, installed at the base of the mast, is operated using a lightweight, reversible power tool with a torque-limiting device for controlled movement. A remote-control switch enables operation from a safe distance of up to three metres, keeping technicians securely on the ground.
Designed for adaptability, the system is suitable for various mast heights and confined spaces, making it ideal for ports, airports, industrial sites, and other large-scale applications.
How it works
The system is installed with a focus on simplicity, safety, and efficiency. The in-tension winch at the mast base eliminates the need for clutches, brakes, or latches. Instead, the luminaire carriage is supported and moved by self-sustaining wire ropes that glide over pulleys at the mast head.
Technicians use a mobile power tool to raise or lower the carriage, with built-in torque control ensuring safe operation. The remote-control feature allows for hands-free, ground-level operation, removing the need for elevated access equipment. All components are factory-prepared, ensuring a smooth and time-efficient installation process.
Case study
Since its introduction, the In-Tension Raise & Lower High Mast System has delivered measurable improvements in safety, reliability, and operational efficiency. Clients report a significant reduction in maintenance-related risks, as all work is now performed from ground level. The elimination of latch mechanisms has resolved the common issue of jammed carriages, reducing maintenance time and costs.
The system’s robust design also extends the lifespan of wire ropes by keeping them in constant tension, reducing wear and tear. Operational disruptions are minimised, with closures limited to the immediate area around the mast rather than large sections of critical infrastructure.
As Dustin Nedohin of Elec-Tech Sales Ltd. in Canada noted:
“The CU Phosco solution keeps operators safely on the ground. Their system is easy to use, simple, safe, and reliable.”
Potential impact
In high-traffic environments like ports and airports, where lighting is essential and downtime is costly, CU Phosco’s system offers a transformative solution. It enhances safety by eliminating work at height, reduces maintenance costs, and improves operational continuity. By addressing long-standing issues with traditional high mast systems, this innovation sets a new benchmark for safety and efficiency in critical infrastructure lighting.
- Date
- 22/07/2025
