Project: Vandersanden – LED high bays, LED stadium lights and LED floodlights
New production hall, yard and facade at Vandersanden in Dilsen-Stokkem, lit with 42 LED high bays, 6 LED stadium lights and 6 LED floodlights: 400 lux, 60% less power and €12,480 saved per year.
For its new 1,600 m² production hall in Dilsen-Stokkem (Belgium), brick manufacturer Vandersanden chose LED inside and out: 42 LED high bays 150W in the hall, 6 LED stadium lights 500W on masts for the yard and 6 LED floodlights 150W on the facade. The hall gets 400 lux on the floor, and the whole site uses 60% less power than a conventional installation would.
- New build: production hall of around 1,600 m² plus yard and facade lighting.
- 42 LED high bays 150W in the hall, switched by motion sensors, delivering 400 lux.
- 6 LED stadium lights 500W on masts for the yard and 6 LED floodlights 150W on the facade.
- 10,200W connected load instead of 25,200W for a comparable conventional installation: 60% less power.
- €12,480 lower electricity costs and 5.9 tonnes less CO2 per year than the conventional alternative.
Project facts
| Client | Vandersanden, brick manufacturer |
| Location | Dilsen-Stokkem, Belgium |
| Building | New production hall, approx. 1,600 m², with yard |
| Completed | 2023 |
| Hall | 42 × LED high bay 150W, 5000K |
| Yard | 6 × LED stadium light 500W on masts |
| Facade | 6 × LED floodlight 150W |
| Mounting | High bays suspended at 8 m, stadium lights on masts at 10 m, floodlights on brackets |
| Control | Motion sensors |
| Illuminance | 400 lux in the hall |
| Planning | DIALux light study |
The starting point
Vandersanden built a new production hall of around 1,600 m² at its site in Dilsen-Stokkem, with a yard for storage and truck traffic around it. There was no existing lighting to replace: the hall, the yard and the facade all had to be lit from scratch.
Three zones, three requirements
The hall needed bright, even light of around 400 lux for production and maintenance. The yard needed powerful light over a large open area for loading and forklift traffic after dark. The facade needed light at the gates and along the building for safe access and security.
Why not conventional lighting
A conventional installation would typically use 400W metal halide high bays in the hall, 1,000W metal halide floodlights on the masts and 400W metal halide floodlights on the facade. That means 25,200W of connected load, warm-up time at every switch-on and regular lamp replacement. Choosing LED in a new build avoids all of that from day one.
The solution
Light study first
Before ordering, we made a DIALux light study of the hall, the yard and the facade. It set out how many luminaires each zone needed and where to place them for even light without glare.
Production hall: 42 LED high bays 150W
In the hall, 42 LED high bays hang at 8 m between the steel roof beams. The luminaire can be set to 90W, 120W or 150W; here it runs at 150W. With 210 lm/W, a 90° beam and daylight white 5000K, they deliver 400 lux on the floor. They are IP65 rated and switched by motion sensors, so they only burn where someone is working. More on choosing wattage and beam in our LED high bay guide.
Yard: 6 LED stadium lights 500W
The yard is lit by 6 LED stadium lights 500W on masts. These are the same luminaires used for sports fields: high output, a 90° beam and daylight white 5000K, so a few masts are enough to light a large open area for loading and forklift traffic. More on lighting large outdoor areas in our LED floodlights collection.
Facade: 6 LED floodlights 150W
Along the facade and above the gates, 6 LED floodlights 150W light the access routes. At 180 lm/W, IP66 protected and with adjustable power and colour temperature, they can be tuned to each spot on the building.
LED luminaires used in this project
Energy savings in figures
Because this is a new build, there was no old installation. The figures below compare the LED installation with the conventional metal halide installation the site would otherwise have needed.
| Conventional | LED | Difference | |
|---|---|---|---|
| Hall | 42 × 400W metal halide | 42 × 150W LED high bay | −10,500W |
| Yard | 6 × 1,000W metal halide | 6 × 500W LED stadium light | −3,000W |
| Facade | 6 × 400W metal halide | 6 × 150W LED floodlight | −1,500W |
| Connected load | 25,200W | 10,200W | −60% |
| Consumption per year | 65,520 kWh | 26,520 kWh | −39,000 kWh |
| Electricity cost per year | €20,966 | €8,486 | −€12,480 |
| CO2 per year | 9.8 t | 4.0 t | −5.9 t |
How we calculated this
- Conventional: 42 × 400W + 6 × 1,000W + 6 × 400W = 25,200W × 2,600 h = 65,520 kWh per year.
- LED: 42 × 150W + 6 × 500W + 6 × 150W = 10,200W × 2,600 h = 26,520 kWh per year.
- Cost: 39,000 kWh × €0.32/kWh = €12,480 per year.
- CO2: 39,000 kWh × 0.15 kg/kWh = 5.9 t per year.
The extra saving from the motion sensors and ballast losses of metal halide lamps are not counted, so the real difference is even larger.
Investment and payback
At current webshop prices, the 54 LED luminaires cost €5,786 (42 high bays, 6 stadium lights and 6 floodlights). Half of the investment was covered by an energy-efficiency subsidy, leaving €2,893. With €12,480 lower electricity costs per year than a conventional installation, that amount is earned back in under three months. Installation and masts are not included in that figure.
Calculate the savings for your site
The calculator below is pre-filled with the Vandersanden figures. Change the values to see what LED would save in your own building, whether it is a new build or a relighting.
Savings calculator
Pre-filled with this project. Power is the average per luminaire (here: 42 high bays, 6 stadium lights and 6 floodlights).
The result
- 400 lux from day one: bright, even light over the whole production hall.
- A safe yard after dark: stadium lights on masts light the loading area and truck routes.
- Lit facade and gates: floodlights for safe access and security around the building.
- 60% less power: 10,200W instead of 25,200W for a comparable conventional installation, plus motion sensors in the hall.
- Lower running costs: €12,480 less on electricity every year and 5.9 tonnes less CO2.
Frequently asked questions
Why use stadium lights to light a company yard?
Stadium lights are built to light large open areas from a few high points. A 500W LED stadium light on a mast covers a large part of a yard on its own, so fewer masts and less cabling are needed than with smaller floodlights.
How do you calculate savings for a new building without old lighting?
We compare the LED installation with the conventional installation the site would otherwise have received: 400W metal halide high bays, 1,000W metal halide floodlights on the masts and 400W metal halide floodlights on the facade. At Vandersanden that difference is 15,000W, or 39,000 kWh and €12,480 a year at 2,600 operating hours.
Why 5000K daylight white in the hall?
5000K gives a crisp, daylight-like light that helps with visual checks on production lines. For warehouses or offices, a warmer 4000K is often preferred; both versions are available.
Can high bays and outdoor lighting be combined in one project?
Yes. At Vandersanden we planned the hall, yard and facade together in one DIALux study and supplied all luminaires in one order, so the light levels and colour temperatures match across the site.
Can you make a free light plan for my site?
Yes. Send us the floor plan and site plan with the ceiling heights. We make a free DIALux light study for the hall, yard and facade, and send a non-binding quote at direct-import prices.
Send us your floor plan and site plan. We prepare a free DIALux light plan and a non-binding quote at direct-import prices, 2 to 4 times below comparable branded luminaires. Delivery throughout the EU, up to 5 years' warranty.
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