LED High Bay Lights: How to Choose the Right Wattage for Your Warehouse
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LED High Bay Lights: How to Choose the Right Wattage for Your Warehouse
Choosing the wrong wattage for a high bay installation is an expensive mistake. Too low and your warehouse is dim and unsafe. Too high and you've overspent on fixtures and electricity. Here's how to get it right.
What Are High Bay Lights?
High bay lights are designed for ceilings 15 feet and above — warehouses, factories, gymnasiums, big-box retail, and agricultural buildings. They produce high lumen output in focused beam patterns to push light down to the working surface from height.
The two main styles:
- UFO High Bays — Round, compact, most popular for warehouses. Easy to install with hook and chain.
- Linear High Bays — Rectangular, better for aisle lighting in racking environments.
Ceiling Height Determines Wattage
The higher the ceiling, the more wattage you need to achieve proper light levels at the floor.
| Ceiling Height | Recommended Wattage | Lumens Needed | Spacing |
|---|---|---|---|
| 15-20 ft | 100W (15,000 lm) | 15,000 lm | 15-20 ft apart |
| 20-25 ft | 150W (22,500 lm) | 22,500 lm | 18-22 ft apart |
| 25-30 ft | 200W (30,000 lm) | 30,000 lm | 20-25 ft apart |
| 30-40 ft | 240W (36,000 lm) | 36,000 lm | 20-25 ft apart |
How to Calculate How Many You Need
Formula: (Room square footage × required foot-candles) ÷ lumens per fixture = number of fixtures
Standard foot-candle requirements for industrial spaces in Ontario:
| Space Type | Foot-Candles Required |
|---|---|
| General warehouse | 20-30 fc |
| Manufacturing floor | 30-50 fc |
| Detailed assembly/inspection | 50-100 fc |
| Loading dock | 20-30 fc |
| Retail (big box) | 30-50 fc |
Example Calculation
10,000 sq ft warehouse, 25 ft ceilings, 30 foot-candles target
- Total lumens needed: 10,000 × 30 = 300,000 lumens
- Using 200W UFO high bays (30,000 lm each)
- Fixtures needed: 300,000 ÷ 30,000 = 10 fixtures
- Layout: 2 rows of 5, evenly spaced
This accounts for light at floor level. Most LED high bays have a Coefficient of Utilization (CU) of about 0.7, so you may want to add a 30% buffer:
- Adjusted: 300,000 ÷ 0.7 = 428,571 ÷ 30,000 = 15 fixtures
A professional lighting layout (which we provide free) gives you exact numbers.
What Each Wattage Replaces
| LED High Bay | Replaces (HID/Metal Halide) | Annual Savings* |
|---|---|---|
| 100W UFO | 250W MH | ~$65/fixture |
| 150W UFO | 400W MH | ~$110/fixture |
| 200W UFO | 500W MH | ~$130/fixture |
| 240W UFO | 750W MH | ~$220/fixture |
*Based on 12 hrs/day, Ontario commercial rate ~$0.13/kWh
UFO vs Linear High Bay
| Feature | UFO High Bay | Linear High Bay |
|---|---|---|
| Beam Angle | 90°-120° | 110°-150° |
| Best For | Open warehouses, workshops | Aisle lighting between racking |
| Mounting | Hook + safety chain | V-hook, chain, or pendant |
| Linkable | No | Yes (some models) |
| Aesthetics | Industrial | Slightly more refined |
Our Linear LED High Bay - 165W is ideal for racking aisles where you need a wide, elongated light distribution.
Key Features to Look For
- IP65 Rating — Dust and water resistant, essential for warehouses, food processing, and agriculture
- 0-10V Dimming — Reduce output during low-activity periods to save energy
- Occupancy Sensor Compatible — Microwave sensors can be integrated for auto-on/off in aisles
- 5000K-5700K Colour Temperature — Industrial standard for maximum visibility
- DLC Listed — Required for utility rebate eligibility in Ontario
All our UFO high bays are IP65 rated and DLC listed.
Installation Considerations
High bay installation requires:
- Proper mounting hardware (hook, chain, safety cable)
- Adequate circuit capacity (200W @ 120V = 1.67A per fixture)
- Appropriate wire gauge for the run length
- ESA permit for new installations in Ontario
For a 20-fixture warehouse, you're looking at 2-3 dedicated 20A circuits.
Our Recommendation
| Ceiling Height | Product | Price |
|---|---|---|
| 15-20 ft | UFO High Bay 100W | $89.99 |
| 20-25 ft | UFO High Bay 150W | $119.99 |
| 25-30 ft | UFO High Bay 200W | $149.99 |
| 30-40 ft | UFO High Bay 240W | $179.99 |
| Aisle lighting | Linear High Bay 165W | $134.99 |
Wholesale pricing for contractors and property managers. Free lighting layout for projects over 10 fixtures.
Need installation? Safer Electric (ESA Licence #7008996) installs high bay lighting in warehouses, factories, and commercial buildings across the GTA. Call (647) 383-9500.
FAQ
How far apart should high bay lights be? As a general rule, spacing equals 1.0-1.5× the mounting height. At 20 feet high, space lights 20-30 feet apart. A photometric layout gives exact spacing.
Do I need a permit for high bay installation? Yes. New fixture installations in Ontario require an ESA permit. Replacing existing fixtures one-for-one may be classified as maintenance.
How long do LED high bays last? Our models are rated 50,000 hours. At 12 hours/day, that's over 11 years before replacement — compared to 2-3 years for metal halide lamps.
Can I dim high bays? Yes. All our UFO high bays support 0-10V dimming. This is commonly used with daylight harvesting sensors in facilities with skylights.