Sri Lanka Airport Signal Upgrade: How GAOQIAO Delivered in 12 Weeks
This case study documents GAOQIAO's delivery of 87 LED signal heads and 2 main controllers for a regional airport upgrade in Sri Lanka. The project demonstrates our approach to fast-track international signal projects.
Project Background
A regional airport in Sri Lanka needed to upgrade its vehicle traffic signal system. The existing system was over 15 years old, with frequent lamp failures and limited spare parts availability. The upgrade needed to:
- Replace 87 signal heads (300mm and 400mm)
- Install 2 main controllers (intersection + runway crossing)
- Add 12 vehicle detectors
- Complete within 12 weeks
- Meet ICAO and local aviation standards
GAOQIAO won the project based on our ability to meet the timeline while delivering EN12368-certified products.
Solution Design
Signal Heads
- 64 × 300mm 3-aspect vehicle signal heads
- 8 × 400mm 3-aspect vehicle signal heads (for high-speed approach)
- 12 × 300mm 2-aspect pedestrian signal heads
- 3 × 400mm arrow signal heads
All heads were 100-240V AC/DC compatible, allowing the airport to use existing cabling where suitable.
Controllers
- 2 × GAOQIAO 22-output main controllers
- 1 × 4-channel conflict monitor unit
- 1 × master time clock with GPS sync
The controllers were programmed with the airport's specific phase diagrams, including the unique runway crossing phase that holds all traffic when aircraft are taxiing.
Detection
- 12 × inductive loop vehicle detectors
- 4 × emergency vehicle preemption inputs
- 1 × UPS backup (4-hour runtime)
Project Timeline
| Week | Activity |
|---|---|
| 1-2 | Design finalization, EN12368 certification paperwork |
| 3-4 | Manufacturing (87 heads, 2 controllers) |
| 5 | QA testing at GAOQIAO factory |
| 6-7 | Ocean freight (Shanghai to Colombo) |
| 8-9 | Local installation by partner team |
| 10 | Commissioning and training |
| 11-12 | Final testing and handover |
GAOQIAO's manufacturing lead time was 3 weeks (faster than the 6-week industry standard for EN12368-certified products). The bottleneck was ocean shipping.
Key Challenges and Solutions
Challenge 1: Tropical Climate
Sri Lanka's coastal location means high humidity, salt air, and intense UV. Standard polycarbonate lenses would yellow in 3-5 years.
Solution: GAOQIAO supplied UV-stabilized lenses with a 10-year anti-yellowing warranty. The housing received extra powder-coating for salt-spray resistance.
Challenge 2: Power Reliability
The airport's mains power had frequent voltage fluctuations. Standard signal heads would fail prematurely.
Solution: All heads were rated for 85-265V AC input, with surge protection rated for the local grid conditions. Each intersection got a dedicated UPS with 4-hour runtime.
Challenge 3: Tropical Storm Season
The upgrade had to complete before the May monsoon. Any delay would push the project into the storm season.
Solution: GAOQIAO maintained a 2-week buffer in the schedule. We manufactured 10% extra units as backup, allowing any damaged unit to be replaced within 24 hours.
Results
The system has been operational for 18 months with:
- 100% uptime (no failures)
- Zero maintenance calls (planned inspections only)
- Successful ICAO compliance audit
- Improved traffic flow at airport entry/exit
- Reduced aircraft-vehicular conflict risk
The airport's engineering team reported high satisfaction with both the product quality and the project execution. GAOQIAO was awarded a follow-on contract for 12 additional intersections at the airport.
Lessons Learned
Three takeaways from this project:
1. Pre-position buffer stock for international projects. Our 10% buffer stock saved the schedule when one head was damaged in transit.
2. Tropical climate needs special materials. Standard products fail faster in coastal tropical environments. Specify UV-stabilized and salt-resistant components.
3. ICAO compliance requires documentation. GAOQIAO provided complete EN12368, ISO 9001, and CE certificates in advance. This avoided customs delays.
Apply This Approach to Your Project
GAOQIAO delivers international traffic signal projects with:
- 3-4 week manufacturing lead time
- EN12368 / CE / ISO 9001 certification
- Flexible shipping (air, sea, or land)
- On-site commissioning support
- 3-year warranty (extendable to 5)
Tell us about your project and we will provide a fixed-price quotation with timeline.
Get a Quote
Email: sky-sale@njgq.net
WhatsApp/Phone: +86-18805173545
Tel: +86-25-84471080
Frequently Asked Questions
What is GAOQIAO's typical lead time?
3-4 weeks for standard products, 6-8 weeks for custom configurations. Rush orders available with 50% surcharge.
Can GAOQIAO handle installation?
We can supervise local installation teams or send engineers for critical projects. Most projects use local contractors with our remote support.
What about warranty?
3 years standard on signal heads and controllers. Extended warranty available to 5 years with annual maintenance contract.
How does GAOQIAO handle international payment?
T/T, L/C, and open account terms for established customers. We work with your preferred payment method.
Related GAOQIAO Products
These public GAOQIAO catalogue pages are related to this article.
- Traffic signal controllersWired and solar controllers with 6-56 outputs.
- LED signal heads200mm, 300mm, 400mm with EN12368 certification.
- Signal polesVertical, signal arm and double-arm configurations.
- Spare partsLED modules, lenses, visors and accessories.