High Bay Lighting Layout Checklist: Ensure ROI & Compliance – Hyperlite

A high-performance lighting system is more than a collection of fixtures; it is a precisely engineered environment designed to maximize productivity, ensure safety, and minimize operational overhead. For facility managers and electrical contractors, the transition from traditional Metal Halide (MH) or High-Pressure Sodium (HPS) systems to LED is often motivated by the promise of rapid Return on Investment (ROI). However, achieving that ROI—and ensuring compliance with modern building codes—hinges entirely on the quality of the initial photometric plan.

The "cost of guessing" in industrial lighting is high. An under-lit warehouse creates Occupational Safety and Health Administration (OSHA) hazards, while an over-lit space wastes energy and capital. A professional lighting layout request is the first step in bridging the gap between a product specification and a high-performance installation. This checklist provides a technical framework for gathering the data necessary to secure a precise, project-ready photometric simulation.

1. Structural Data: The Blueprint of Precision

The accuracy of a lighting simulation is limited by the quality of the spatial data provided. In professional lighting design, the gold standard is a scaled CAD (.dwg or .dxf) file. While PDFs are common, they often lack the layer data necessary for lighting designers to quickly identify structural nuances.

Dimensional Essentials

Ceiling Height (Deck vs. Mounting Height): It is a frequent mistake to provide only the total ceiling height. Designers require the mounting height, which is the distance from the floor to the bottom of the luminaire. According to the Illuminating Engineering Society (IES), mounting height significantly impacts the "spacing-to-mounting-height ratio," which determines how many fixtures are needed to achieve uniform light.
Obstructions and Encroachments: Industrial spaces are rarely empty boxes. HVAC ductwork, fire suppression sprinkler systems, and structural steel columns can create significant shadows or "dead zones." A useful heuristic is to mark all obstructions larger than 24 inches on the plan. Ignoring these can lead to illuminance errors of up to 15% in critical work zones.

Surface Reflectance Values

Reflectance is the percentage of light that "bounces" off surfaces. Standard assumptions (e.g., 80% for ceilings, 50% for walls, 20% for floors) are often used, but they can be misleading. For instance, a facility with polished concrete floors will have a much higher reflectance than one with dark, oil-stained asphalt, potentially reducing the number of fixtures required.

LED High Bay lights illuminating an empty high-ceiling warehouse with rows of gondola shelving for retail or storage layouts

2. Operational Context: Defining Activity Zones

Uniform lighting across a 100,000-square-foot facility is often inefficient and may violate energy codes like ASHRAE 90.1-2022. Professionals categorize spaces into "Activity Zones" to optimize light placement.

Zoning for Efficiency

High-Rack Storage: Requires vertical illuminance to ensure labels are readable from the floor to the top pallet. This often necessitates "aisle-lighter" optics rather than standard wide-beam circular fixtures.
Open Staging/Receiving: According to industry-standard LED Warehouse Lighting Buyers Guides, recommended foot-candle (fc) levels for receiving and staging areas typically range between 15 fc and 60 fc, depending on the complexity of the task.
Manufacturing/Assembly: These areas require higher lux levels and high Color Rendering Index (CRI) values to ensure color accuracy and reduce eye strain.

Zone Type	Recommended Illuminance (fc)	Target Uniformity (Max:Avg)
Bulk Storage (Inactive)	5–10 fc	4:1
Picking/Packing (Active)	30–50 fc	3:1
Fine Assembly/QC	50–100 fc	2:1
Loading Docks	20–30 fc	3:1

Note: Values based on IES RP-7 industrial lighting recommendations.

3. Technical Specifications and Compliance Framework

A layout request must specify the performance standards the project aims to meet. This ensures that the suggested fixtures are not just "bright," but compliant with local and federal regulations.

The Role of IES LM-79 and LM-80

To build a trustworthy layout, designers use .ies files derived from IES LM-79-19 reports. These reports provide the "performance scorecard" of a fixture, detailing its total lumens, efficacy (lm/W), and light distribution. Furthermore, IES LM-80-21 data is used to project the long-term lumen maintenance of the LED chips, ensuring the facility stays bright throughout its 50,000+ hour lifespan.

Regulatory Compliance

DLC Premium Qualification: For B2B projects, DesignLights Consortium (DLC) QPL status is often a non-negotiable requirement. It is the primary prerequisite for securing utility rebates, which can cover 30% to 50% of the fixture cost.
Energy Codes: Projects in California must adhere to California Title 24, Part 6, which mandates specific lighting power densities (LPD) and automatic controls.
Safety Listings: Every fixture in the layout should be UL Listed or ETL Listed to meet National Electrical Code (NEC) safety standards.

LED High Bay fixtures lighting a high-ceiling industrial warehouse assembly floor with visible HVAC ducts and structural elements.

4. ROI Simulation: The Financial Impact of Precision

A professional lighting layout serves as the foundation for an accurate ROI calculation. By simulating the exact wattage and count of fixtures, facility managers can project energy savings with high confidence.

Case Study: The 50-Fixture Warehouse Retrofit

Based on a simulation for a medium-sized facility replacing 400W Metal Halide fixtures (458W total system draw) with 150W LED high bays, the financial impact is substantial:

Operating Hours: 6,000 annual hours (16h/day, 300 days/year).
Electricity Rate: $0.18/kWh (California/Northeast average).
Annual Energy Savings: $16,632.
Maintenance Savings: $4,125 (elimination of bulb/ballast replacements).
HVAC Cooling Credit: $715 (LEDs emit less heat, reducing cooling load).
Total Annual Savings: $21,472.

With an estimated project cost of $12,500 and a $2,500 rebate from the DSIRE Database programs, the payback period is approximately 3.6 months. This demonstrates that high-performance lighting is a capital investment that essentially pays for itself within a single fiscal quarter.

5. Controls and Smart Integration

The most common oversight in layout requests is failing to specify control preferences upfront. Modern industrial lighting is rarely "always on."

Mandatory Control Strategies

0-10V Dimming: The industry standard for simple, reliable light level adjustment.
Occupancy/Vacancy Sensors: According to DOE FEMP guidance, wireless occupancy sensors in inactive storage zones can deliver an additional 25% energy savings.
Daylight Harvesting: In facilities with skylights, sensors can dim LEDs when natural light is sufficient, further reducing the LPD.

LED High Bay lights and UFO high bay fixtures illuminating a high-ceiling warehouse with storage racks and a forklift.

Expert Troubleshooting: Common Layout Pitfalls

Experienced lighting auditors identify several "friction points" that can derail a project during installation:

The "Visual Parallax" Error: Designers often assume a perfectly flat floor. In older facilities, floor slopes or mezzanine levels can change the effective mounting height, leading to uneven light "pools."
Ignoring the NEC Wire Class: When specifying 0-10V dimming, contractors must distinguish between Class 1 and Class 2 wiring. Mixing these in the same conduit can lead to code violations and interference.
Spectral Inconsistency: Ensure the Color Correlated Temperature (CCT) is consistent. Mixing 4000K and 5000K fixtures in the same open space creates a "patchwork" ceiling that is visually fatiguing for workers.

Summary Checklist for a Lighting Layout Request

Before submitting your request to a lighting designer or manufacturer, ensure you have the following data points ready:

[ ] Scaled Floor Plan: CAD (.dwg) preferred; PDF with at least one known dimension as a second choice.
[ ] Mounting Height: Distance from the floor to the bottom of the intended fixture.
[ ] Voltage Requirements: (e.g., 120-277V or 480V).
[ ] Target Foot-Candles: Based on IES RP-7 or specific task needs.
[ ] Reflectance Data: Note if floors are polished, walls are dark, or ceilings are open-truss.
[ ] Obstruction Map: Location of HVAC ducts, cranes, or high-density racking.
[ ] Control Requirements: Specify if 0-10V dimming, occupancy sensors, or Title 24 compliance is needed.
[ ] Rebate Eligibility: ZIP code and utility provider to check the DSIRE Database.

By providing this comprehensive data set, you enable the lighting designer to move beyond generic estimates and deliver a "solid" photometric plan that guarantees performance, compliance, and a verifiable ROI.

YMYL Disclaimer: This article is for informational purposes only and does not constitute professional electrical engineering or legal advice. Lighting designs must comply with local building codes and the National Electrical Code (NEC). Always consult with a licensed electrical contractor or certified lighting professional before beginning an installation.

Your Checklist for a High Bay Lighting Layout Request