What could go wrong—and how to solve it, according to our project managers.
This guide is written for teams planning or executing custom LED display projects—owners, GCs, architects, integrators, and marketing teams. We use a “Problem → Root Cause → How to Fix” structure so you can turn it into a practical checklist for bids, design reviews, and site coordination.
What goes wrong: Grainy text at close range, or overspec’ed pixels that inflate cost and content workload.
Root cause: Pixel pitch chosen without coupling screen size, viewing distance, and content type.
How to fix:
Define primary viewing distance and content type (text, faces, fast-motion ads).
First-pass rule of thumb:
Best clarity distance ≈ pixel pitch (mm) × 1–1.2
Acceptable distance ≈ pixel pitch (mm) × 1.5–2
Prioritize matched resolution and area over chasing the smallest pitch.
Validate with a 1:1 content slice or partial mockup before PO.
Custom LED Screen Projects Ekintry
Quick check: Target resolution = (width/pitch) × (height/pitch); minimum text size verified at target distance; content team has approved templates.
What goes wrong: Too dim in sunlight, overexposed at night, or harsh reflections indoors.
Root cause: “Brighter is better” without ambient light, façade reflection, or local rules.
How to fix:
Typical ranges: Indoor 600–1200 nit, semi-outdoor/shop window 1500–3000 nit, outdoor 4000–6000+ nit (latitude/orientation dependent).
Add ambient light sensors and time-of-day dimming curves.
Improve contrast with sun-shades, black masks, and anti-glare surface finishes.
Quick check: Daylight readability; auto-dimming after dark; brightness compliance confirmed with property/city.
What goes wrong: Visible seams, panel misalignment, movement in storms, safety concerns.
Root cause: Treating “panel mass” as the only load; ignoring wind, dynamic loads, drainage, and maintenance access.
How to fix:
Run calcs to local code for dead/live/wind/seismic loads.
Design a maintainable frame: front/back service path ≥ 600 mm; consistent service direction.
Drainage details: top drip edges, rear channels, grommeted cable penetrations.
Coordinate with façade/glazing teams to avoid secondary leaks.
Quick check: Stamped structural drawings; corrosion protection grade fits environment; installation & service routes defined.
What goes wrong: Breakers trip at full-white scenes; color drift from heat; thermal throttling in summer.
Root cause: Sizing only to average power; no thermal plan for control rooms/windows.
How to fix:
Size distribution to peak power with 20–30% headroom; balance across three phases.
Plan airflow: louvered returns/ducted paths; for shop windows, front-in/back-out airflow or a small dedicated AC.
Calculate voltage drop; ensure equipotential bonding and proper earthing; consider PDU metering for O&M.
Quick check: One-line/route drawings; peak-scene thermal test records; ground resistance within spec.
What goes wrong: Wrong aspect ratio, jagged edges, latency in switching.
Root cause: Player/processor/control specs don’t match target resolution/refresh and input types.
How to fix:
Lock target canvas resolution and input types (HDMI/SDI/NDI/Network) during design.
Use pro processors for multi-signal, EDID control, and seamless switching.
Standardize content workflows: aspect, frame rate, and bitrate templates.
Quick check: Device list shows max load resolution/bitrate; on-site test has no stretching/black bars.
What goes wrong: Intermittent noise; unstable long-distance feeds.
Root cause: Weak/strong power lines run together; poor shielding; long runs without regeneration.
How to fix:
Separate low-voltage data from mains; use shielded cable and metal trays.
Convert to fiber for long runs; add repeaters or distributed senders; ring redundancy where critical.
Implement proper earthing, surge, and lightning protection in the control room.
Quick check: Cable plan shows spacing; BER/jitter tests pass on longest links.
What goes wrong: Different hue/brightness across the canvas; seams visible in flat fields.
Root cause: Mixed LED/IC batches; missing factory/onsite calibration.
How to fix:
Single-batch supply; incoming QA on grayscale/gamut; full-screen per-pixel calibration after install.
Keep 3–5% spare parts from the same bin/batch for future swaps.
Quick check: Factory and on-site calibration files archived; spares mapped to on-wall positions.
What goes wrong: Leaks in rainy seasons; salt-spray corrosion; sand abrasion.
Root cause: Misapplied IP ratings; coastal/high-salt upgrades missing.
How to fix:
Typical: Front IP65, rear IP54 for outdoor; add stainless fasteners, anti-corrosion coats, thicker seals in harsh zones.
Use watertight glands for cable I/O; overlap joints to avoid “upstream seams.”
Quick check: Third-party IP test; 24–48 h spray/soak records at critical joints.
What goes wrong: Frame rework; clashes with fire routes or façade hardware; service paneling impossible.
Root cause: Relying only on design drawings; no laser scan/BIM clash tests or mockups.
How to fix:
Pre-install laser survey; BIM clash review for façade/M&E; mock a sample arc/segment for curved/irregular builds.
Early “collision list” with GC/façade/M&E teams.
Quick check: As-built survey report; mockup photos and punch-list closeouts.
What goes wrong: Dented corners, crushed crates, missed go-live dates.
Root cause: Wrong crate spec; incomplete customs/standards paperwork.
How to fix:
Packaging standard: corner protectors, anti-shock foam, internal restraints; critical parts in dedicated crates.
Pre-clear certifications (CE/UKCA/RoHS/EMC) and HS paperwork; list spares separately for customs.
Quick check: Unboxing checklist; cargo insurance; complete compliance dossier.
LED Screens packaging
What goes wrong: No fast swap for a failed module; color drift uncorrected.
Root cause: No spare strategy; no remote access/alerting.
How to fix:
Stock 3–5% modules, PSUs, receiver cards, and key cables from the same batch.
Enable remote access on processors/players; set alerts for temperature/current/online rate.
Annual service: cleaning, firmware, re-calibration.
Quick check: Spare map & logbook; remote accounts handed over and tested.
What goes wrong: “Just extend it a bit” spirals budget/timeline.
Root cause: Vague specs; unclear trade boundaries.
How to fix:
Put resolution, area, brightness, control, structural interfaces, and power into the technical annex as payment baselines.
Route all changes through written impact analysis (cost/time/risk) with signatures.
Milestone plan: order → shipment → installation → light-up → handover tied to payment schedule.
Quick check: Drawings match annex; change orders closed; milestones tracked.
What goes wrong: Complaints, shutdown orders, failed plan checks.
Root cause: Local requirements not reviewed early; fire/egress conflicts.
How to fix:
Pre-review brightness schedules, façade alteration permits, fire and service access.
Line up CE/UKCA/RoHS/EMC reports; archive with O&M pack at handover.
Quick check: Permit/notification records; third-party test reports; O&M manual delivered.
Mall atrium column-wrap / curved displays
Focus: radius, seam control, front-service.
Approach: flexible/curved cabinets; custom mapping in processor; segment mockup + per-pixel calibration.
High-glare shop window
Focus: high brightness with low reflection; day/night dimming; heat.
Approach: ≥ 2500 nit, assess glass reflections; ducted airflow or small dedicated AC; separate daytime/night LUTs.
Rooftop / façade outdoor wall
Focus: wind, lightning/earthing, service access.
Approach: co-engineer with façade; graded surge/earthing; top drip edge, rear drainage; balanced three-phase power.
Processor load vs. target canvas verified
Peak power and circuit headroom confirmed
Ambient sensor + dimming schedule applied
Flatness, seam gap, and flushness spot-checked
Waterproof joints, drainage path, seal compression inspected
Factory + on-site calibration reports archived
Redundant signal path and remote access tested
Spare parts received, labeled, and logged
O&M manual, emergency plan, contact list delivered
Permits, DoCs, and certifications filed
Design first: We propose three pitch–distance–budget options early, with brightness and power estimates.
Structural coordination: We run clash checks with GC/façade/M&E and deliver install and service routes.
Remote-guided installation: With accurate site data (dimensions, angles, anchors, power), we issue full install and cabling drawings so the on-site team can assemble and connect by drawing.
Maintenance plan: Remote accounts and alerts come pre-configured; same-batch spares are shipped with the kit for hour-level recovery of minor failures.
Have a live project? Share dimensions, viewing distance, indoor/outdoor, content type, and civil/MEP constraints. We’ll reply with a deployable technical & budget brief that cuts guesswork and keeps your screen on time, on spec, and on budget.
