Why We Use Marine-Grade, Virgin Brass

You are a lighting professional.

And whether you’re new to the industry or can remember having to keep a voltage meter in your back pocket, your customers count on your expertise. And you, in turn, rely on manufacturers to provide materials that will last.

But have you experienced the frustration because that beautiful powder coated aluminum fixture you installed 2 years ago has already begun to chip and corrode?

And what about the PVC well lights with aluminum covers? Sure, they were less expensive but how quickly did the PVC turn gray and the aluminum lose its paint?

Don’t you wish these fixtures would last as long as you were told they would?

Then there’s brass. We all know it’s better than powder coated aluminum and plastic but did you also know not all brass is the same quality?

Brass and other metals ready to be recycled

After working with dozens of engineers and material specialists since 2011, we found out the truth! Our team discovered that many manufacturers continue to use recycled brass but that virgin, “pure” brass really is the better material for several reasons:

Recycled brass is made from an enormous variety of discarded objects often containing non-brass metals. They are thrown together, melted down and poured into molds for new products. And, in most cases, nothing is done to remove impurities like lead and aluminum, which can lead to pitting and an overall faded looking fixture.

Recycled brass contaminants can also have differing melting temperatures and corrosion resistance, which can create small cavities compromising the structural integrity of a fixture during and after production.

Because of what we’ve found we now exclusively use marine-grade, virgin brass to manufacture our fixtures so they’ll last longer and look better for all of your projects.

Don’t lose any more time or customers because of flaking powder, fading plastic, or broken brass fixtures. You don’t plan on quitting in five years, so why would you choose a product that won’t last that long?

If you haven’t already, give us a call today at 703-454-8207 and learn more about how Sterling Lighting can help you grow your business.

Why We Chose NOT to Use LED Bulbs

LED has become the hottest buzz phrase in the lighting industry today. LED bulbs are cheaper, easy to replace, and easily interchangeable. However, for all the benefits, there are still many limitations. That’s why Sterling Lighting’s fixtures feature integrated LEDs instead.

Many people ask us how we came to this decision. It ultimately came down to one question: “What is best for our customers?” After considering our collective experiences with LEDs, our engineers’ advice, and the mistakes of others currently manufacturing LEDs, we knew that integrated LEDs were the best choice.

The Problem with LEDs

The biggest issue with LED bulbs is heat.  95% of LED bulbs installed in landscape lights today are not designed for an enclosed fixture.  Most LED mr16 bulbs are designed to have air circulate around them, such as for track lighting and recessed lights (this usage is very popular in Europe and Asia). These types of fixtures do not encapsulate the bulbs and therefore allow heat to dissipate.

Drawing heat away from the LED is a challenge that every engineer faces when designing bulbs. That’s why you often see heat sinks such as fins, air gaps, etc. built into LEDs. When LED bulbs are tested alone in an ideal setting, such as a laboratory, they perform very successfully.  The problem is that an open air, indoor test is much different than the real conditions of a sunny, 100-degree day when the bulb is inside an enclosed brass or aluminum fixture. The result is a dramatically reduced performance when installed on a property.

In fact, many bulbs will see lumen depreciation in the first few months and burnout in the first year.  This is not a new problem. One of the largest LED bulb companies told us that they experience a 3% failure of their bulbs in the first year. This number only continues to climb as time goes on, and it could reach a 25-30% failure rate by the third year.  For a landscape lighting professional who installs 100 systems a year with an average 20 lights per system, the number of problem bulbs quickly becomes overwhelming.

Our Experience with LEDs

We personally have encountered problems with LEDs as well. We began using LED bulbs in 2010. After testing bulbs from seven different original equipment manufacturers (OEMs), we settled on the one we believed to be the highest quality. We were able to save 80% in energy efficiency and use less wire and smaller transformers, but ultimately, we experienced too high of a failure rate to make the bulbs worthwhile. Even though our OEM guaranteed that the LED was designed for an enclosed fixture, the heat buildup was too great and caused the bulbs to burn out.

Why Is There a Discrepancy?

This is a puzzling situation: If LEDs have major problems with heat dissipation, why are there so many LEDs on the market that are supposedly designed for closed fixtures? One reason is that some OEMs are willing to bend the truth in order to make a sale. There are also design companies that will roll the dice and use an LED bulb even though the OEM specifically states that the bulb is not designed for an enclosed fixture. Ignoring the realities of the technology and marketing LEDs for closed fixtures is simply not sustainable.

The Solution

In order to provide the best option for our customers given these limitations, we had a few choices:

  • Design an LED mr16 bulb that could be used in an enclosed fixture. This would have required a very low lumen output in order to reduce the risk of failure. (Which is why you see many low-lumen bulbs on the market.) However, 200-350 lumens just isn’t bright enough for many professional lighting designs.
  • Design our own fully integrated LED. While this option posed many challenges (perfectly matching the LED and driver with the fixture, ease of changing parts, lumen output, etc.), we knew this was the only way to ensure the quality we were looking for.

So, we took on the challenge and designed Sterling Lighting’s signature integrated LED with the best of both worlds: high lumen output, ease of changing parts, premium components and proper heat sinking. We know that this product is one of the best on the market, and we hope you’ll be as pleased with the overall performance as we are.

In an upcoming post, we will break down every decision in designing our fixture and compare our product to the others on the market. Stay tuned!

 

Color Temperature Was Essential When Designing Our LED Light Fittings

When we first began working with LED lighting there were a number of prerequisites for us to put our name to the Sterling Lighting fixtures. We needed the light fitting to look visually beautiful, for it be durable and last under various outdoor weather conditions and be fitted with LED bulbs that are rock solid. Above all though, the right color temperature and light output was essential.

Our product development started with using a traditional 35 watt par 36 bulb. This light provided a more even spread than the standard MR 16 bulb used in many fittings which is so important when lighting up a landscape. Once we were able to perfectly match a par bulb, we began to look for ways to improve and enhance it.

We first increased the color temperature by a 100 degrees. This may only sound like a minor difference, but adjusting the temperature slightly can have a big impact in the overall result. Too cool and the light can appear too white and wash everything out especially in an outdoor garden setting and have it too warm the light can be too strong and overpower the subject you are wanting to highlight.

Further into our product development we noticed that a halogen bulb gave a “hot spot” near the fixture.   Our objective wasn’t to just recreate the exact same look using an LED bulb, we wanted to make the best light source possible. So we chose to incorporate a Cree chip that is known for not producing an intense spot near the fixture itself.

You might notice that Sterling Lighting LED fittings distribute light from side to side as well as front top to bottom. The optics we had also designed helped distribute the light more evenly and further afield than the usual par bulb could.

So with these modifications, we started to achieve the quality of light we wanted to see within landscape projects to enhance design elements, architecture and gardens. We are very happy with the results and can proudly stamp out Sterling Lighting brand our fixtures!

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Pros and Cons Series of Light Fixture Materials

Pros and Cons Series of Light Fixture Materials

When we design any light fitting we are extremely conscious of not only the light output but also the quality of the fixture. The materiality of outdoor lighting fixtures is important not only from a visual perspective but also from a durability standpoint. So what should you know when selecting the best fixture for your project and clients?

In this series we will discuss the pros and cons of various materials used in outdoor lighting and provide you with the necessary information when specifying and selecting fixtures with your clients.

Aluminium light fittings

Let’s start with is aluminium as aluminium fixtures are seen on many if not most lighting installations out there today. As with anything, there are different grades of aluminium. If you are using a fixture that uses a machined piece of aircraft quality, virgin aluminium, it will obviously perform much better than the typical cast aluminium fixture. Unfortunately there are very few fixtures made using the premium quality aluminium which will affect the durability of the fitting.

The benefits of aluminium

There are some benefits of using aluminium as a material in the production of light fittings. These include:

  • Light weight
  • Resistant to rust
  • Inexpensive compared with brass or copper
  • Good conductor of heat (aluminium fixtures can be used to draw heat away from LED lights
  • Easy to mould into the shape required for the design of the fixture
  • Easy to finish with a paint or powder coat in any color imaginable

The number one reason aluminium fixtures are so popular is that they are typically 1/3 the price of the quality brass or copper fixtures.

The drawbacks of aluminium fixtures

  • The surface pitts causing the powder coat or paint finish to no longer adhere to the fixture
  • The material corrodes causing the fixture to first look chalky before it starts to dissolve
  • The paint or powder coat finish will fade over time in the sun

These drawbacks are why most manufactures will have short warranties on the finish if they provide any warranty at all. Aluminium is not recommended by most companies to ever use in salt water environments as the salty air will destroy these fixtures quickly. Just some of the reasons at Sterling Lighting we don’t include aluminium fittings in our lighting collection.

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Designing The Perfect Path Light

If you haven’t already noticed, we are obsessed with quality path lights. Not only are path lights required for safety purposes, they also play a large role in the appearance of your garden in the evening light. From the installation side of things, we have installed thousands of path lights in the gardens residential properties. Our experience tells us that the most problematic fixture has been the path light. If you have also had experience installing path lights for a period of time, you probably have a list of issues with the fixtures you have used.

path-light

Common problems with path lights

Some of these problems include, but are not limited to, aluminium path lights with a 1/4″ stem that seem to always break at the stake, premium sand cast path lights that are so top heavy that they need to be cemented in to keep from leaning and finally companies using copper plumbing parts and simply gluing them together.

Another common issue we have incurred is the lack of light output. Many companies restrict the light output by constructing metal bars in the front connecting the stem to the hat of the path light. This creates odd shadows and doesn’t help disperse the light evenly across the surface.

 
Finding the solution

path-light2We decided in order to find the perfect path light, we would have to design it ourselves! The first thing we decided the path light fixture need be was an integrated led fixture. We developed a path light using a Cree CXA chip, 4 watt, 400 lumen light source.

We decided on using a heavy duty 1.25″ solid virgin cast brass stake. We gave the fixture a 9″ abs ground stake and a 20″ cast brass stem. We recommend burying 6″ of the stem in the ground along with the 9″ stake. That is a total of 15″ of the fixture in the ground which allowed us to have a solid base to ensure the path lights will always be perfectly straight and not keel over.

path-light3Every component of the fixture is threaded together with no glue in sight. This give the fixture tremendous strength. We even threaded our lens into the fixture itself. The lens is twice as thick as any lens on the market. If it were ever broken, it is designed to simply be replaced.

Besides the path light being able to withstand just about anything one could throw at it, it also gives an amazing light output which is so important to us. This fixture will create a 14″ circle of light. The light source is completely hidden from within the fixture to enhance its visual appearance. We even designed an 18″ extension stake if someone would like a taller path light within their garden.

In our opinion, this is the most durable, beautiful, path light ever made that will tick all the boxes for those who are installing the fixture and we are sure will meet the expectations of the end user.

 

path light

path light