Case Study: How Charleston Saved $1.2M on lamp Pole Replacements
How Did Charleston Save $1.2M on Street Lights? Discover their smart switch to cast aluminum lamp poles with military-grade rust-resistant coating - cutting replacements by 65%! Learn why coastal cities are choosing these rust-proof cast iron outdoor lamp alternatives that look historic but last decades. [See the breakthrough] #SmartCities #CostSavings
“How Did a Coastal City Slash Its Lighting Budget—Without Sacrificing Quality?”
Charleston, South Carolina—a city famous for its historic charm and brutal coastal weather—had a problem. Salt air and humidity were devouring their cast iron lamp poles, forcing costly replacements every 8-10 years. Then they tried something radical… and saved $1.2 million in 5 years.
At Hengsheng Casting, we helped make it happen. Here’s the real-world breakdown (with numbers you can trust):
✔ The Problem: Why traditional poles failed so fast
✔ The Solution: Switching to rust-proof cast aluminum lamp poles + advanced coatings
✔ The Results: 65% fewer replacements, happier taxpayers
Spoiler: This isn’t just a Charleston story—your city could be next.
The Challenge: Salt Air vs. Historic Lighting
Charleston’s Nightmare (Sound Familiar?)
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300+ cast iron lamp poles along the Battery seawall
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40% showed severe rust after just 6 years
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$385,000/year in replacements/repaints
“We were stuck in a cycle: install, rust, repeat.”
— Charleston Public Works Director
Why Traditional Iron Failed
🔴 Cast Iron: Beautiful but porous—salt moisture seeped in
🔴 Standard Paint: Peeled within 2 years near the coast
🔴 Bolt Corrosion: Stainless steel hardware still rusted
The Solution: Smarter Materials + Science-Backed Coatings
Step 1: The Material Switch
After testing 4 options, Charleston chose:
✅ Hengsheng’s Cast Aluminum Lamp Poles
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Naturally rust-proof (zero iron = zero rust)
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30% lighter = easier hurricane-season removals
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Passed 150mph wind testing
Step 2: Next-Level Protection
Even aluminum needs armor in Charleston! We added:
✔ Marine-Grade Powder Coating (SaltSpray® Technology)
✔ Stainless Steel Hardware (316L grade—the same used on ocean oil rigs)
✔ Internal Wax Sealant (For hidden cavity protection)
Fun Fact: Our coating is tested to last 25+ years in accelerated salt-fog chambers.
The Installation: Minimizing Downtime
Phased Rollout (What Worked)
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Pilot Program: 50 poles along worst-hit seawall section
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Public Feedback: Residents loved the identical historic look
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Full Scale-Up: 250 more poles over 18 months
Smart Swaps You Can Steal
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Reused existing lamp heads (saved $175/unit)
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Our pre-assembled bases cut install time by 40%
The Results: By the Numbers
| Metric | Before (Cast Iron) | After (Our Aluminum) |
|---|---|---|
| Lifespan | 6-8 years | 25+ year warranty |
| Annual Repairs | 37 poles/year | 6 poles/year |
| Cost per Pole (20 yrs) | $4,200 | $1,900 |
| Taxpayer Complaints | 22/year | 3/year |
Translation: Charleston’s ROI = 3.7 years—then pure savings.
Why This Worked (And How to Copy It)
1. Aluminum ≠ “Cheap” Anymore
Modern casting replicates ornate iron designs perfectly.
2. Coatings Are Everything
Our rust-resistant coating includes:
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Self-healing properties for minor scratches
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UV blockers to prevent fading
3. Future-Proof Upgrades
Added features Charleston loves:
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LED-ready wiring channels
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QR code tags for maintenance tracking
Your City’s Turn: 3 Steps to Start
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Test a Sample Pole: We’ll ship one for free—see/hear/feel the difference.
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Run the Numbers: Use our Cost Calculator for your exact climate.
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Phase Smartly: Prioritize worst-condition areas first.
“This isn’t spending—it’s stopping wasteful spending.”
— Charleston Mayor’s Office
Ready to Write Your Own Success Story?
📞 Call +8613833705565
📧 Email:admin@hengshenggreenhouse.com
“Proven from Charleston to Cork—salt air doesn’t have to win.”
More Real-World Examples:
Why choose Hengsheng Casting ?
● Established in 1988, the first foundry in China to undertake outdoor garden products and municipal products in Europe and the United States.
● The founder has 60 years of rich production experience in the foundry industry, and has always adhered to the rigorous attitude of excellence in the production of products.
● There are 10 engineers of professional and experienced.
● Strong production capacity: The factory covers an area of 40,000 square meters, has 128 employees, and annual sales of RMB 100 million. Over the past 36 years, more than 18,000 containers of municipal products have been exported abroad.
● Strictly implements the quality system certification: ISO9001:2015. from Mould design to casting production , every process has strictly quality control .
● We use raw materials that meet international standards to ensure that the material of the product fully meets customer requirements.
● Cooperate with more than 20 professional municipal product manufacturers abroad with a history of more than 50 years.
● Customized service and confidentiality agreement, can be customized according to the customer's design. Sign a confidentiality agreement to strictly protect the customer's exclusive design.
● After sales warranty service: to meet the needs of cooperative customers to the maximum extent possible.
● Our cooperation purpose: to grow and develop together with customers, achieve win-win cooperation! Become a strategic partner.
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FAQS
Q1: How do I contact you? A: Please click contact us or send email: admin@hengshengcasting.com to us or call us at +86-13833705565
Q2: What kind of transportation method do you use? A: By sea freight. Generally, it's from Tianjin Port, and the port can be chosen.
Q3: How to get a quotation? A: Please let us know the products are needed? And tell us the quantity and packing method etc, So that we can give you a details quotation.
Q4: Do you accept custom orders? A: Yes, we provide custom made service. For custom orders, these items may also be ordered by calling or emailing us. Please include all specifications, and attach pictures or drawings (if needed), include (if applies) your design that you want to have designed per your specifications. Designers and or custom builders welcome.
Q5: If can sign a confidentiality agreement? A: we will protect your own design and sign the confidentiality agreement with you
Q6: What's your payment method? And what's the proportion of the deposit? A: T/T (30% deposit, and 70% of the balance to be paid upon seeing the copy of the bill of lading). LC at sight plus 30% deposit by T/T.
