Ceiling height: the parameter that changes everything
Ceiling height is the first parameter to qualify before any source selection. A fitting dimensioned for 4 m height placed at 10 m delivers insufficient illuminance and poor uniformity. Conversely, an oversized highbay at low height generates glare and direct energy waste.
We select fittings according to their real photometric curve, verified by simulation, to guarantee target lux levels at working height regardless of the installation height.
LED highbay: selection criteria
- Luminous flux : from 10,000 lm (small warehouses) to 60,000+ lm for great heights
- Beam angle : narrow (60°) for high aisles, wide (120°) for open zones
- IP rating : minimum IP65, IP66 for dusty zones or areas subject to high-pressure cleaning
- IK rating : IK08 to IK10 depending on exposure to impacts (forklift trucks, handling)
- Colour temperature : 4000-5000 K to maximise visual acuity in work zones
Illuminance levels by zone per EN 12464-1
| Zone | Required illuminance (lux) | Max UGR | Min CRI | Note |
|---|---|---|---|---|
| Simple storage (no reading) | 100 lux | UGR 25 | CRI 60 | Regulatory minimum, insufficient for picking |
| Picking / preparation zone | 300 lux | UGR 25 | CRI 80 | Reading codes, labels, quality control |
| Quality control station | 500 lux | UGR 19 | CRI 80 | Fine visual task, supplementary lighting possible |
| Loading / unloading dock | 200 lux | UGR 25 | CRI 60 | IP65+, impact resistance IK08 |
| Vehicle circulation aisles | 150-200 lux | UGR 25 | CRI 60 | Uniformity critical for safety |
| Integrated offices | 500 lux | UGR 19 | CRI 80 | Office standard, transition from warehouse |
Reducing the energy bill: concrete levers
A warehouse often operates continuously or over extended hours. Lighting represents a significant share of total electricity consumption, and it is precisely where the return on investment of a well-dimensioned LED installation is fastest.
- Replacement of sodium or metal halide highbays : 50 to 70% saving on lighting consumption
- Presence detection per aisle : unoccupied aisles switch to standby at 10-20% flux, instant restart on approach
- Dimming according to natural light input : automatic compensation via roof-mounted luminosity sensors
- Zone metering : identification of zones with high optimisation potential
Frequently asked questions
Can existing highbays be replaced without rewiring?
In most cases, yes. Current LED highbays are available as direct replacements (same fitting, same supply) or with the existing ballast retained. We verify electrical compatibility before any recommendation to avoid installation surprises.
Does presence detection work with forklift trucks?
Yes, provided the right type of detector is selected. Standard passive infrared sensors detect human movement but may be less reactive to a forklift with an enclosed cab. In that case we favour microwave sensors or combined solutions, with a delay calibrated to the handling cycles.
Conclusion
Warehouse lighting is first and foremost a performance issue: operator safety, team productivity and energy cost control. At Rodalight, every logistics project is dimensioned on the basis of EN 12464-1 standards, with a photometric simulation before installation and implementation follow-up.
For associated work spaces, see our page office lighting or our page institutional lighting. To scope your project, start with our personalised study or express advice.
