High Bay LED Lighting for Warehouses, Factories, and Large Facilities

What ceiling heights are considered high bay?

High bay applications typically start around 15 feet and extend to about 45 feet. Below that range, the same lumen package can create glare and non-uniformity; above that range, optic selection and spacing discipline become the primary drivers of uniformity on the work plane.

How do I choose lumen output for a warehouse or factory?

Select lumen output based on mounting height, target maintained light level, and the optical distribution. As mounting height increases, higher lumen packages and narrower optics are often required to maintain uniformity and reduce scalloping between fixtures. Use IES photometrics and a layout to validate average illuminance and max-to-min ratios for the task.

What beam angles work best at different mounting heights?

Narrower distributions are commonly used at higher mounting heights to push light to the work plane and control glare, while wider distributions are used at lower mounting heights to improve spacing and uniformity. Confirm the distribution using the fixture’s IES file and verify spacing-to-mounting-height assumptions in a layout rather than relying on a single rule.

When should I use UFO high bays vs linear high bays?

UFO high bays are commonly selected for open areas where omnidirectional coverage and compact form factor are helpful. Linear high bays are often used over aisles and production lines where a rectangular distribution can reduce wasted light outside the target zone. The correct choice is driven by bay geometry, racking orientation, and whether the goal is wide-area coverage or aisle-optimized distribution.

What color temperature is typical for high bay lighting?

4000K is commonly used for general warehouse and manufacturing environments where visual comfort and clarity are both priorities. 5000K is often specified for higher-visibility tasks or inspection zones where contrast recognition is emphasized. Keep CCT consistent within a space to avoid visible patchiness across large ceilings.

What CRI is appropriate for warehouses and manufacturing?

80 CRI is common for general industrial work where identification and reading are routine. Higher CRI is typically reserved for color-critical tasks, inspection, or packaging areas where accurate color discrimination is required. Specify CRI based on the task instead of defaulting to the highest value.

How do I prevent glare from high bay fixtures?

Glare control is primarily managed through optic selection, mounting height, and spacing. Use distributions matched to the ceiling height, avoid over-lumening at lower heights, and consider lower-glare options where workers have frequent upward sightlines. Verify predicted UGR or other glare metrics when available, and validate with a layout rather than fixture count alone.

Do I need occupancy sensors in warehouses?

Occupancy sensors are commonly used in aisles, low-traffic storage zones, and areas with intermittent activity to reduce runtime. In continuously occupied production zones, sensors may provide limited benefit unless paired with dim-to-low strategies. Confirm sensor coverage patterns at the mounting height and coordinate timeouts with operational needs to avoid nuisance switching.

What is the role of 0–10V dimming in high bay systems?

0–10V dimming enables stepped or continuous output reduction for energy management, sensor integration, and daylight response. In large facilities, dimming can also support commissioning adjustments to address over-lighting or non-uniformity after installation. Verify driver compatibility and control zoning early to avoid rework.

How does daylight harvesting apply in high-ceiling facilities?

In skylit buildings, daylight harvesting can reduce energy use if the control zones align with daylight penetration patterns and sensors are placed to avoid false readings from bright spots. The system should be commissioned for the actual space conditions and racking layout, since storage changes can alter daylight distribution over time.

What environmental ratings matter for industrial high bay lighting?

Confirm the location rating (dry, damp, or wet) and any requirements for dust, moisture, or washdown exposure. In facilities with airborne particulates, chemical exposure, or frequent cleaning, housing and lens materials should be selected for durability and compatibility with the environment. Also verify impact resistance where fixtures are exposed to equipment contact.

How do I decide between 120–277V and 277–480V fixtures?

Select voltage based on the facility’s available branch circuits and electrical distribution. Using the correct input voltage reduces the need for transformers and simplifies installation. Verify driver input range and any control voltage requirements, especially when integrating sensors or centralized controls.

What maintenance factors should be checked before specifying high bays?

Review rated life, driver serviceability, thermal management, and access method. In high-ceiling spaces, lift time is often the dominant maintenance cost, so longer-life components and stable lumen maintenance are typically prioritized. If lens material is a decision point, consider impact resistance and long-term clarity based on the environment and cleaning practices.

Why do some high bay retrofits feel uneven after installation?

Uneven results usually trace to lumen packages or optics that do not match the mounting height, fixture spacing that does not align with the distribution, or a layout that was not validated with photometrics. Racking, obstructions, and changing reflectances can also shift the delivered light to the work plane. A photometric plan using the selected SKU’s IES file is the fastest way to identify the cause.

How should high bay spacing be planned for aisles with racking?

Align fixtures with aisle centerlines and use distributions intended for aisle coverage to keep light on the travel and pick zones rather than on top of racks. Consider asymmetric options where the goal is to push light into vertical faces. Validate with a layout at the actual mounting height and aisle width to confirm uniformity and vertical illuminance targets.