Ally Helps Steel Manufacturing Plant Meet Sustainability Objectives

Steelscape is a steel manufacturing company with locations in Washington and California. As a producer of Energy Star and LEED-approved metal roofing products, Steelscape fosters a workplace culture and business philosophy based on safety and environmental stewardship. When they wanted to improve lighting at their Washington facility, they turned to Ally for the project’s audit, design, and turnkey implementation.

After a comprehensive audit, Ally determined that a LED lighting retrofit with sensor controls would save Steelscape tens of thousands of dollars annually in energy costs while improving occupant comfort and streamlining lighting maintenance.

LED Lights and Sensors

By replacing the existing metal halide and fluorescent lights with more efficient LED lighting and sensor-based controls. Ally improved lighting quality throughout the facility while reducing annual utility costs by nearly $70,000. To extend fixture life, Ally used industrial-grade frames and chassis designed to resist corrosion in heat and steam-rich environments.

Implementation Plan

With numerous assembly line configurations, multiple cranes moving in and out of the facility, ceiling heights soaring up to ninety feet in places, project layout and implementation were critically essential to streamline ongoing maintenance. Ally used the same lighting systems throughout the facility with configuration modifications. To account for extreme ceiling height, Ally used wireless controls, which allow for greater distance between sensors and fixtures. Finally, selecting LED lights, which have longer lifespans significantly (up to 100,000 hours) than other options, reduces maintenance risks associated with constantly working on lights positioned at extreme heights.

Utility Costs Financing Offset

Nearly half of the project was financed by utility rebates and incentives, while the rest was offset by the savings generated by improved efficiency. In just under three years, the project will have paid for itself in saved utility costs, with a total of nearly $500,000 of cash flow freed up over the first ten-year period.