Old Trafford Floodlight Installation

Scope

Vertical Access was appointed to support the replacement and upgrade of the stadium’s existing floodlighting system to meet the latest Premier League and UEFA Champions League broadcasting requirements.

The works involved removing the existing floodlights and installing new LED units beneath the stadium canopies, alongside associated lifting, structural and installation works. The project had to be completed while maintaining the day-to-day operation of the stadium and without conventional scaffolding or MEWPs positioned on the pitch.

The Challenge

The location of the floodlights beneath the stadium canopies presented a significant access and logistical challenge. Traditional scaffolding would have been prohibitively expensive, while restrictions preventing MEWPs from accessing the grass pitch removed another conventional method of reaching the work areas.

The size and positioning of the new lighting units also required a carefully coordinated lifting and installation strategy. With the stadium remaining operational, the programme needed to accommodate other activities while responding to design changes and additional works identified as the installation progressed.

Our Response

Vertical Access worked closely with Musco from the design stage to develop a specialist access, lifting and installation strategy for the new floodlighting system.

Prior to commencing on site, the team met with the client to review the lighting units and provide input into the proposed design, lifting methodology and installation sequence. Drawing on more than 20 years of experience undertaking floodlight installation and maintenance within stadium environments, the team developed an approach that avoided the need for extensive scaffolding or access from the pitch.

Close coordination continued throughout the project, allowing the team to respond to design changes and additional requirements as they arose. This included undertaking structural checks and repairs and assisting with the lifting and positioning of additional equipment.

Particular consideration was given to the cable apertures penetrating the existing roof cladding. Vertical Access worked alongside Musco to develop a bespoke waterproofing detail around these penetrations, protecting the roof while accommodating the new electrical infrastructure.

Bespoke digital recording applications were also developed for the project, providing installers with a defined installation protocol and creating an auditable record of the completed works. Regular management visits and site safety inspections supported the installation throughout the programme.

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Outcome & Feedback

The floodlighting upgrade was successfully completed without impacting the day-to-day operation of the stadium or requiring conventional access from the grass pitch.

The new LED installation provides the stadium with a modern, world-class floodlighting system capable of meeting the demanding broadcasting requirements of Premier League and UEFA Champions League football.

The bespoke waterproofing solution developed for the roof penetrations has remained leak-free, while the digital installation records provide the client with a comprehensive and auditable record of the completed works.