Warehouse high-bay lighting: layout, optics and sensors

Why high bays are a top retrofit

Warehouses, shops and distribution centres often run long hours, and many still have metal halide or high-pressure sodium fixtures, or older T5 high-output fluorescents. Those are some of the best candidates for an LED upgrade because the wattage drop is large and every relamp at height costs lift time and labour.

A good high-bay project is more than swapping fixtures one for one. Choosing the right optics and controls usually matters more than the fixture brand. For the money side, see what drives LED retrofit payback.

Mounting height, fixture type and layout

High-bay fixtures are designed for tall ceilings and low-bay fixtures for lower ones. The exact cut-off varies by manufacturer, so choose by the photometric data rather than the name. Round fixtures suit open floors, and linear fixtures suit aisles and long work areas.

• Ask for a photometric layout. A designer models the space and shows light levels and uniformity before you buy.
• Keep spacing within what the fixture's photometrics support for your mounting height, or you will get bright and dark bands.
• Plan for the racking you will have, not just what is there today.
• Look at vertical light on rack faces, not just horizontal light on the floor. Pickers read labels on vertical surfaces.

Optics for racking aisles

In open floor areas, a wide distribution spreads light evenly. In narrow racking aisles, the same wide optic throws much of its light on the tops of the racks, where nobody needs it. An aisle optic directs light along the aisle and onto the rack faces.

Mount fixtures centred over the aisle and clear of sprinkler heads and racking. Any time racks are moved or added, review the lighting at the same time.

Sensors and dimming

LED fixtures turn on instantly and dim smoothly, so occupancy sensors finally work well in warehouses. Metal halide needed minutes to warm up and could not be switched often, so it usually ran all shift.

A common approach is one sensor zone per aisle. Fixtures dim to a low level when the aisle is empty and come up to full when a forklift or person enters.

Daylight sensors near skylights and overhead doors add more savings. Read more in our lighting controls guide.

Cold buildings, dust and moisture

Many Alberta warehouses and shops are lightly heated or unheated, and cold storage runs below freezing all year. LEDs actually perform well in the cold, but check the rated operating temperature for each fixture and its sensors.

• When warm, moist air meets cold fixtures, condensation can form. Choose sealed fixtures with an appropriate IP rating where this happens.
• Wash bays and food areas need fixtures rated for wash-down.
• Dusty areas such as woodshops and grain handling need sealed fixtures. Some areas may be classified as hazardous locations and need specially rated equipment. That is a design decision for a qualified professional.
• Fixtures and sensors near overhead doors take blasts of cold air every time a door opens in January, so pick products rated for it.

Safety, maintenance and planning the work

• Install fixtures with safety cables and keep them clear of forklift masts and crane paths.
• Make sure emergency lighting still covers aisles and exits after the change. See emergency and exit lighting.
• Plan lift access and work zones around operations, often at night or on weekends.
• Recycle old metal halide lamps and fluorescent tubes, which contain mercury.

We handle design, phasing and installation through our LED retrofit and plant retrofit services, with online job reporting so you can track progress.

Common questions