Why Continuous-Run Wiring Strategy Matters in Long Industrial Installations
Continuous-run LED strip lighting is commonly specified for warehouses, distribution centers, and manufacturing facilities due to its uniform illumination and efficient installation. While fixture selection often receives attention, wiring topology within long runs is a primary determinant of voltage stability, reliability, and serviceability.
For runs exceeding 100 feet—and especially those approaching or exceeding 200 feet—the choice between internal fixture-to-fixture bridging and external feed-through wiring becomes a critical design decision. Improper selection frequently results in uneven light output, nuisance failures, or premature component stress.
Electrical Realities of Long Strip Light Runs
All continuous lighting systems are constrained by basic electrical principles. As conductor length increases, resistance rises, resulting in voltage drop and uneven current delivery across the run.
In long strip light installations, this manifests as:
- Reduced light output at the end of the run
- Increased thermal stress on upstream drivers
- Inconsistent dimming behavior
- Accelerated component aging
While short runs can tolerate modest voltage drop, extended warehouse installations cannot.
Internal Bridging Architecture
Internal bridging refers to factory-installed wiring that passes power through each fixture in sequence. This approach simplifies installation and minimizes external wiring labor.
| Characteristic | Internal Bridging | Operational Impact |
|---|---|---|
| Installation speed | High | Reduced labor on short runs |
| Maximum practical run length | Typically <100 ft | Voltage drop becomes limiting |
| Conductor size | Fixed by manufacturer | Limited flexibility |
| Failure propagation | High | Single fault may disable downstream fixtures |
Internal bridging performs adequately in short rows but becomes increasingly risky as run length increases.
External Bridging and Multi-Feed Designs
External bridging uses independent conductors routed outside the fixture housings, often with multiple power feeds introduced along the run.
| Characteristic | External Bridging | Operational Impact |
|---|---|---|
| Installation complexity | Moderate | Requires planning and coordination |
| Voltage stability | High | Consistent lumen output |
| Feed redundancy | Configurable | Improved fault tolerance |
| Scalability | Excellent | Suitable for 200+ ft runs |
For large warehouses, external bridging is often the only viable method to maintain uniform performance.
Voltage Drop and Load Distribution Over Distance
Voltage drop increases linearly with distance and load. Internal bridging concentrates current draw at the beginning of the run, while external multi-feed designs distribute electrical load more evenly.
| Run Length | Internal Bridging | External Bridging |
|---|---|---|
| 50–100 ft | Acceptable | Acceptable |
| 100–150 ft | Marginal | Stable |
| 150–200+ ft | High failure risk | Recommended |
Serviceability and Failure Isolation
Maintenance considerations are often overlooked during design but become critical over time.
Internal bridging increases the likelihood that:
- A single fixture failure disables multiple downstream units
- Troubleshooting requires sequential fixture removal
- Production areas experience extended outages
External bridging isolates failures, allowing individual fixtures to be serviced without impacting the entire run.
Related Commercial Lighting Categories
For warehouse runs exceeding 100 feet, and especially those approaching 200 feet, external bridging with distributed power feeds provides superior voltage stability, fault isolation, and long-term reliability compared to internal fixture-to-fixture wiring.
Brandon Waldrop
As the lead technical specialist for our commercial lighting technical operations, Brandon Waldrop brings over 20 years of industry experience in product specification, outside sales, and industrial lighting applications.
His career began in physical lighting showrooms, where he focused on hands-on product performance and technical support. He later transitioned into commercial outside sales, working directly with architects, electrical contractors, and facility managers to translate complex lighting requirements into energy-efficient, code-compliant solutions.
Today, Brandon applies that industry experience to architect high-performance digital catalogs and technical content systems, helping commercial partners streamline the specification process and deploy lighting solutions with total technical confidence.
