Controlled procedures for the civil and mechanical installation of elevated and inset AGL fixtures — base-can positioning, level and alignment, grouting, drainage, earthing, cable entry and sealing, shallow/deep base installation, fixture mounting and torque, frangible couplings, and foundation, civil-interface and pavement-interface inspection.
Important — Final dimensions, tolerances, installation depths, torque values, drainage arrangements, grout specifications and foundation details shall be taken from the approved project drawings, equipment manufacturer's installation instructions and applicable airport/regulatory requirements. Do not substitute generic dimensions or torque values where manufacturer-specific values are available.
To establish a controlled procedure for installing AGL base cans to the approved location, elevation, orientation and structural requirements.
Verify:
The base can shall be:
Critical Requirement — Base-can position shall be established from approved survey/control references, not by visual estimation alone.
To ensure that each base can is installed at the correct horizontal position.
To ensure that the base can is installed at the correct elevation relative to the finished pavement.
The installed base can shall meet the approved elevation and tolerance requirements.
Note — Incorrect alignment can affect fixture orientation and subsequent photometric performance.
To ensure correct angular and directional alignment of the base can.
Prohibited Condition — Do not compensate for an incorrectly positioned base can by using excessive or uncontrolled grout thickness.
To establish the procedure for securing and stabilizing a base can using the specified grout or concrete system.
Verify:
Important — The drainage arrangement shall not compromise pavement integrity or permit uncontrolled water migration into electrical infrastructure.
To prevent water accumulation inside base cans and associated equipment cavities.
Verify:
A drainage check shall be performed before fixture installation.
Critical Rule — Do not rely on incidental contact between the base can and surrounding concrete or earth as a designed electrical connection.
To provide the required bonding/earthing arrangement for metallic AGL base cans and associated equipment where specified.
To ensure that cables enter the base can safely without damage or excessive mechanical stress.
To prevent water, moisture, contaminants and unwanted material from entering the base can through cable entries.
Cable entries shall provide the protection specified by the approved design and equipment manufacturer.
Particular Attention — Verify that the shallow base installation does not compromise pavement structural integrity or required aircraft/vehicle clearance.
To control installation of shallow AGL bases where the approved design specifies shallow mounting.
To control installation of deep base cans where greater foundation depth or equipment arrangement is required.
Excavation work shall follow the project's approved excavation and underground-service safety procedures.
To ensure AGL fixtures are correctly mounted and mechanically secured.
Critical Rule — Never substitute a generic torque value when the fixture manufacturer provides a specific approved value. Over-tightening may damage the fixture or mounting surface; under-tightening may permit movement or loosening.
To ensure fixture fasteners are tightened according to approved manufacturer's requirements.
Use:
Critical Requirement — The frangible element shall not be modified or substituted with an unapproved component.
To ensure frangible couplings are installed correctly and maintain the intended frangibility characteristics.
To ensure fixture mounting hardware is correctly installed.
Check
After Installation
To verify that an AGL fixture is installed at the approved elevation.
Fixture height can affect:
Note — For directional fixtures, orientation is a critical photometric parameter.
To ensure each fixture is oriented according to the approved design.
To ensure fixtures form the intended geometric pattern.
To verify that AGL foundations meet approved structural and installation requirements before equipment installation.
Check:
Any significant defect or deviation shall be recorded and evaluated before proceeding.
To verify the interface between AGL electrical equipment and associated civil works.
Check:
Civil and electrical teams shall jointly inspect critical interfaces before final closure.
Critical Requirement — The final AGL installation shall provide a safe and controlled transition between the fixture/base-can assembly and the surrounding pavement, without creating an unacceptable aircraft, vehicle, drainage, structural or FOD hazard.
To ensure that AGL equipment installed within or adjacent to pavement is correctly integrated with the pavement system.
Geometry
Mechanical
Civil
Electrical
Operational
Common installation sequence, hold points, defect checklist and the golden rule that apply across all 21 Division 04 procedures.
The recommended installation sequence is:
The following activities should be treated as inspection hold points where required by the project ITP:
During inspection, specifically look for:
Never
Always
The AGL installation team should maintain, as applicable:
"Install the AGL foundation correctly before installing the light. Verify location, elevation, alignment, drainage, cable entry and pavement interface before final fixing. Then mount, torque, orient and align the fixture according to the approved design and manufacturer requirements."
Each airport should adapt these SOPs to its own approved project drawings, equipment manufacturer's installation instructions, civil works specifications, structural/geotechnical requirements, ITP/hold-point regime, and applicable national and international airport infrastructure requirements.
Approved project drawings and manufacturer-specific values shall take precedence wherever they impose more restrictive or more specific requirements than these SOPs.
Technical references behind the procedures in this division:
References are given at document or chapter level for technical orientation. Confirm the current edition, amendments and national adoption (for example DGCA CAR Section 4, FAA Advisory Circulars or EASA material) for each project. Approved project specifications, manufacturer instructions and the airport's own procedures take precedence, as stated in the precedence note above.
Quick answers about Civil Works, Base Cans & Mounting SOPs in the AGL SOP Library.
Division 04 is a set of 21 procedures (SOP-79 to SOP-99, Rev 0) for the civil and mechanical installation of elevated and inset AGL fixtures. It covers base-can positioning, level and alignment, grouting, drainage, earthing, cable entry and sealing, shallow and deep bases, fixture mounting and torque, frangible couplings, and foundation, civil-interface and pavement-interface inspection.
No. Final dimensions, tolerances, installation depths, torque values, drainage arrangements, grout specifications and foundation details must come from approved project drawings, the manufacturer's installation instructions and applicable airport or regulatory requirements. Generic values must not be substituted where manufacturer-specific values exist.
Where required by the project ITP, hold points HP-01 to HP-10 cover base-can location, elevation and orientation, cable entry, drainage, foundation, fixture mounting, fixture height, fixture orientation and the pavement interface. The base must not be permanently fixed until its location has been verified.
Survey, excavate, prepare foundation, position the base can, verify level and alignment, then cable entry, drainage, earthing and bonding, fixing or grouting, cure and inspect. Then install the fixture, torque, align, check height, check the pavement interface, make the electrical connection, test, do the FOD inspection and release.
Never substitute a generic torque value when the manufacturer provides an approved one (SOP-91). Use a calibrated torque wrench, verify its calibration status, tighten progressively where required to the specified torque, and record the verification. Over-tightening can damage the fixture or surface; under-tightening can allow movement.
The frangible element must not be modified or replaced with an unapproved component (SOP-92). Verify the approved type and identification, inspect for damage, install per manufacturer instructions, and do not drill, weld or otherwise alter the coupling. Then verify fixture height and vertical alignment and record the installation.
Drainage (SOP-84) must not compromise pavement integrity or let water migrate into electrical infrastructure. Verify the outlet, path, absence of blockage and no water accumulation before fixture installation. Cable entries (SOP-87) must be cleaned, fitted with approved glands or seals at the correct compression, inspected and any defective sealing recorded.
Incorrect base-can location, elevation or orientation, base-can movement, poor grouting, cracked concrete, blocked drainage, unsealed cable entries, damaged cable insulation, incorrect transformer connection, loose fasteners, incorrect torque, damaged frangible coupling, and incorrect fixture alignment, height or orientation.
Knowing the installation procedure is essential. Understanding why base can placement, backfill and mounting tolerances matter to long-term AGL performance takes deeper technical knowledge.
Learn through structured training covering:
Develop the technical foundation to work with AGL systems systematically, safely and confidently.
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