Emergency Light Battery Replacement Case Study

The Challenge: Chronic Failures & Costly Callbacks

Every year during the mandated 90-minute battery test, 20–30% of Harbor Tower’s emergency lights failed. The facility management faced several recurring headaches:

• Sealed lead-acid (SLA) batteries self-discharged too quickly.
• Temperature swings near exit doors accelerated battery degradation.
• The maintenance team had to re-test failed units, then replace batteries – often paying costly after-hours rates.

Annual SLA Cost Breakdown (Before):

1. Replacement SLA batteries (60 units/year @ $18) = $1,080
2. Labor for testing, re-testing, and replacing = 35 hours @ $45/hr = $1,575
3. After-hours emergency callouts (average 3 per year) = $1,200
4. Total = $3,855 per year – just for keeping the lights compliant.

“Every December, I knew I’d get angry calls from tenants who saw flickering exit signs. We’d rush to fix them, pay overtime, and still fail the final inspection once every two years.” — Lisa M., Facility Manager

The Surlon Power Solution: Drop-In Lithium Replacements

As a leading lithium battery manufacturer, Surlon Power provided our advanced 12.8V 3Ah emergency light lithium batteries as direct drop-in replacements for the building's existing 6V and 12V SLA units. Installation was done in-house by two electricians over three weekends with zero wiring changes – just unplug the SLA and plug in the Surlon lithium battery.

Why Surlon Lithium is the Ultimate Upgrade:

• 10-Year Design Life: Eliminates the vicious cycle of annual replacements.
• Thermal Stability: Wide temperature range (-20°C to +60°C) keeps performance stable, even near drafty exterior doors.
• Ultra-Low Self-Discharge: (<2% per month) guarantees the battery passes the 90-minute test even after 11 months of standby.
• Certified Reliability: UL 924 listed and fully compliant with NFPA 101 standards, manufactured in our ISO-certified facilities.

The Results: 24 Months of Zero Failures

By switching to lithium, Harbor Tower drastically reduced their operational overhead. Here is the data collected over two years:

Financial Impact: The building achieved a 100% reduction in test failures and saved $4,910 over two years.

Additional Benefit: The building passed its fire inspection on the first attempt – for the first time in 6 years.

What the Facility Manager Says Now

“Honestly, I forgot we even had emergency lights for over a year. That’s the goal. No calls, no surprises, no extra budget requests. The Surlon lithium batteries cost less over time and just work.”
— Lisa M., Facility Manager

Key Takeaway for Building Operators

An emergency light lithium battery is not an expense – it’s a labor-saving, compliance-assuring investment. For buildings with 50+ units, payback is typically under 12 months. Ensure your building is safe, compliant, and cost-efficient.

Find the Right Lithium Replacement for Your Emergency Lights →