Did you know that approximately 5% of warehouse workers experience an injury on the job every year? Most of these injuries could have been prevented with effective safety programs and proper lighting.
As an electrical contractor, your goal should be to install high-quality, reliable lighting systems. When the application is for a fast-paced warehouse bustling with activity, the right lighting system facilitates seamless operations and enhances workplace safety. It can also improve employee performance by reducing work errors and potential damage to the property. A quality lighting system can also improve employees' concentration levels, resulting in a productive work environment.
Here are some best practices to follow when installing or retrofitting warehouse lighting systems.
Understand the needs of the warehouse.
Warehouses are unique depending on their layout and use. There is no one-size-fits-all approach for light placements in warehouses. Understanding the specific usage of the facility is essential for determining the best lighting arrangement.
A warehouse is usually divided into various sections such as the loading areas, order packing zones, storage areas, and others. Determining what tasks are conducted in each of these areas will give you a good sense of the ideal light levels.
For example, loading areas are generally crowded with forklifts, conveyors, or boom lifts. To ensure the safety of workers and equipment, it is important to use the appropriate lights in such areas. One of our Lighting Specialists, Tyler, recommends that in warehouses where the ceiling height is 20 - 25 ft we typically suggest 22,500 lumens 150 watt LED UFO high bay lights. For ceiling heights over 35 ft, we've found 45,000 lumens 300 watt LED UFO high bay lights are a great fit. This said, he always recommends a photometric study for new construction warehouses. This helps identify the best fixture for the desired light level. Administrative offices within warehouses require cool lighting for easy reading and writing. Offices typically have a 2x2 or 2x4 grid ceiling and our LED panels that match the grid size. We typically recommend 5000k color temperature lights to achieve the cool lighting that's often desired in this type of space.
Select the best location for luminaires.
Now that you know that every area in the warehouse needs a custom lighting solution, focus on finding the right locations for each luminaire to ensure an optimal layout. Failing to appropriately layout the space could easily result in non-uniform light distribution, poor visibility, and glare. Complete your lighting layout plan well before you begin work to avoid this risk.
Choose locations that illuminate the entire area uniformly, thereby helping the workers perform their tasks efficiently. For example, placing luminaires on the ceiling above storage areas could create shadows or dark spots once materials begin stacking up. This can lead to accidents in the workplace. In some cases, placing luminaires over the top of the shelves will be beneficial to illuminate the racks.
Similarly, the aisles should be properly lit as they are frequented by heavy moving equipment, such as forklifts, boom lifts, and hand trucks.
Select the right luminaires.
To create an ideal work environment in a warehouse, it is essential to install luminaires outfitted with the appropriate specifications and options. LED luminaires are ideal for warehouses for many reasons, such as high output, low maintenance, reduced energy consumption, and long product life. Choose a high-quality but cost-effective LED luminaire to outfit the entire warehouse area.
Because warehouses feature large open spaces, it is necessary to determine the intensity of light required for illumination. Most commercial warehouses need light levels from 20 to 40 footcandles. Understand the warehouse layout and its sections before calculating the lighting levels required for each space.
Depending on the area that requires illumination, choose either Type I or Type V light distribution. As the name suggests, Type I refers to a tight beam of light emitted from the source. Conversely, Type V is a light beam emitting light in an inverted V covering a circular or square area.
If you have observed glare issues in the warehouse, it is best to use anti-glare LED luminaires. You can also use frosted lenses or install reflectors on existing luminaires to eliminate glare.
Adopt smart lighting systems.
Installing LED luminaires with smart controls can help reduce energy usage and waste. This cost-effective lighting solution can reduce energy usage by up to 30% as lights can be turned on and off based on whether an employee is in that area of the warehouse or not.
You can also install dimmers or timers to control the light output in areas that are not being used. Similarly, luminaires equipped with motion sensors or occupancy sensors can automatically detect motion to turn on the lights. In the absence of motion, the light is automatically switched off.
Undertake regular luminaire maintenance.
Proper maintenance of luminaires can ensure that standard quality of light is distributed across all areas of the warehouses.
Check and replace the luminaires that are no longer producing enough light. If you have a multi-lamp fitting, replace the non-working components.
Check the luminaires for loose connections or wiring problems and fix them accordingly.
Clean the fixture lenses in the warehouses to remove dirt, debris, and dust. This can increase the light level.
Wipe the luminaires and diffusers clean to remove the dirt accumulated on the exterior parts.
Discard outdated and inefficient lamps and replace them with high-performing ones, such as with LEDs.
Consider redesigning the lighting layout if the warehouse layout has been altered from its original plan.
Conclusion
Electrical contractors can leverage their expertise in various lighting systems to build a safe and secure environment in warehouses. Follow the best practices outlined above to design excellent lighting solutions for your customers.
Cory Peterson is Director of Sales & Marketing at LED Lighting Supply where he focuses on improving customer experience and revenue operations. Cory writes about commercial, industrial and sport lighting, along with topics important to contractors and facility managers. In his free time, Cory enjoys traveling, snorkeling, boxing and cooking. He can be reached at [email protected].
Warehouses are somewhat unique when it comes to commercial lighting. They are often large buildings, lit by hard-to-reach fixtures, and may hold hundreds of workers and thousands of pieces of inventory and equipment. This level of foot traffic, not to mention operation of dangerous machinery and logistical equipment, requires optimal lighting for the prevention of injuries, mistakes, and accidents. Read on for more on the importance of efficient warehouse lighting.
A poorly arranged lighting installation can cause a drain on energy. Fixtures may be placed and installed in a way that causes light to be directed improperly. Things like racking and shelving must be considered before lighting is installed, which if often not the case, especially in older warehouses. Poor design can also make it hard for workers to read labels, find products, and operate machinery without experiencing high levels of glare. This is extremely dangerous to workers and inventory, so properly placed lighting is absolutely key in any warehouse. Color rendering index (CRI) must also be considered to ensure workers can see clearly throughout the entire property. A general rule of thumb is to avoid warehouse lighting systems with CRI ratings of less than 85.
Many warehouses operate 24/7, and must, therefore, be outfitted with the most efficient and long-lasting lighting possible. Otherwise, lights will burn out quickly and require a lot of costly maintenance and frequent replacement. The lifespan of LED warehouse lighting is around 50,000 hours, which, with around-the-clock operation, equates to about seven years. LEDs can be paired with a variety of features in order to promote longevity and reduce waste while lights are not needed. An LED lighting system is a great way for large properties, such as warehouses, to properly illuminate their entire buildings while simultaneously reducing energy waste and keeping costs down.
Warehouses are often spaces where dangerous machinery is operated daily. Accordingly, the Occupational Safety and Health Administration (OSHA) has issued specific requirements for warehouse lighting. These requirements are intended to keep workers safe from accident and injury due to the inability to see properly. Two terms to keep in mind when talking about proper lighting for this application – lux and lumens. The amount of light cast on a surface is termed illuminance and is measured in lux. Lumens is the total output of visible light from a light source. In warehouses, OSHA requires the following:
A minimum of 2 lumens per square foot in areas with heavy equipment use
300-400 lux for warehouse loading bays
100-200 lux for warehouse aisles
200 lux for lobbies, stairwells, and corridors
750 lux for factories and workshops
500 lux for laboratories, offices, and showrooms
OSHA also requires the following safety standards in regard to lighting fixtures:
No exposed live parts
Firm mounting to walls
No openings large enough for a finger to fit through
Placement at least 7 feet above work surfaces or an OSHA-compliant shatter-proof shield
Warehouses and other commercial businesses that do not comply with OSHA run the risk of receiving numerous fines so it’s always best practice to research OSHA guidelines for your industry.
In the event of an emergency, lighting can be a critical part of preventing injury or even saving lives. OSHA recommends compliance with the National Fire Protection Agency’s guidance around emergency lighting, which includes the following:
All exit signs must be properly lit so that employees with normal vision can see along the exit routes
Each exit must be marked with a sign reading “exit”
Exit signs must be clearly visible for 90 minutes in a power outage/when lights go out
Emergency lighting must provide no less than 10.8 lux illumination along the exit route
Emergency lighting must be tested for brightness and battery life every 30 days
Functional testing of emergency lighting must be conducted annually for no less than 1.5 hours if the system is battery-powered
The Americans with Disabilities Act also lays out a number of safety guidelines in public places, for which there are also fines for non-compliance. It is important to work with a lighting professional when installing your warehouse lights. A professional can help ensure your warehouse lighting is in compliance with OSHA and following relevant guidance to ensure your space is safe for workers at all times.
According to a study conducted by Georgia Power, lighting is the largest energy expense in a warehouse. A major way warehouse owners and managers can cut down on energy expenses is by upgrading their commercial lighting fixtures with the assistance of a lighting professional. Many warehouses contain outdated, fluorescent high bays, metal halides, and other fixtures that keep energy costs high due to things like high switching rates and high maintenance costs. LED technology makes it easier to install long-lasting fixtures that do not need to be replaced frequently and provide high-quality lumen output. In fact, upgrading to LED fixtures has been known to generate savings for warehouses of approximately 61%. Adding compatible motion sensors and other features can save up to 70% more energy in the long term, and your lighting service can help match you with energy-focused rebates from local utility companies. Upgrading warehouse lighting is a smart choice for anyone looking to reduce their emissions and save on energy expenses.
Warehouses have specific requirements when it comes to lighting. Products like LED linear lamps, LED high bay fixtures, LED emergency lights and exit signs, can update any warehouse and make it a safer and more efficient work environment. Control systems, such as timers and dimmers, are also recommended, especially in warehouses that operate 24/7. A lighting technician can help choose the best lighting fixtures for your specific commercial space. Warehouse lighting must be selected with worker safety, lifespan, and quality in mind. Examples of recommended warehouse lighting products include:
Linear High Bay LED Warehouse Ceiling Lights
LED Low Bay Warehouse Ceiling Lights
LED UFO High Bay Lights
High Bay LED Vapor Tight Warehouse Light Fixtures
LED Emergency Combo Lighting
If you are interested in upgrading your warehouse lighting, contact Bay Lighting today. We equip warehouses in Maryland, D.C., and Virginia with state-of-the-art lighting solutions that improve safety conditions and overall efficiency. Call 301-858-9494 to get started.