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Everything on LED high bay lighting: standard values, luminaire selection, cost calculator and segment comparison for industry, warehouses, workshops and sports halls.
The right LED high bay lighting reduces energy costs compared to conventional HQL/HID systems by typically 50–70%, meets the requirements of DIN EN 12464-1 and pays for itself in under three years in typical industrial projects. This guide shows you which luminaire types, illuminance values and light planning parameters are decisive for your facility – from the small workshop to the production hall spanning several thousand square metres.
Conventional hall lighting using mercury vapour (HQL) or sodium vapour lamps consumes two to three times more electricity than modern LED systems. Add to this long warm-up times, frequent lamp replacements and high maintenance costs due to difficult-to-access mounting heights.
LED high bays start instantly, are widely dimmable and achieve service lives of 50,000 to 100,000 operating hours. At 16 hours of operation per day, 50,000 hours equates to a calculated service life of over 8 years without a lamp change.
The Ecodesign Regulation (EU) 2019/2020 (in force since September 2021) also tightens minimum requirements for luminous efficacy and service life – a further reason to replace outdated systems now.
The DIN EN 12464-1:2021-11 is the central standard for lighting at indoor workplaces. It specifies maintained illuminance values (Em), maximum glare values (UGR) and colour rendering indices (Ra) for all typical work areas.
The ASR A3.4 (Technical Rule for Workplaces) is aligned with DIN EN 12464-1: anyone who plans in accordance with DIN generally meets the requirements of ASR A3.4 at the same time. For areas at risk of explosion, additional ATEX directives apply – more on this in our guide ATEX & Ex-Protection LED Lighting.
| Area | Em (Lux) | UGR max. | Ra min. |
|---|---|---|---|
| Traffic routes without pedestrians | 20 | 28 | 40 |
| Traffic routes with pedestrians | 150 | 25 | 60 |
| Loading bays | 150 | 25 | 60 |
| High-bay racking face | 200 | 25 | 60 |
| Packing / order picking | 300 | 25 | 80 |
| General production | 300–500 | 22 | 80 |
| Precision assembly / quality control | 500–1,000 | 19 | 90 |
| Sports halls (DIN EN 12193, Class III) | 300 | 22 | 65 |
The UGR value and its significance for glare-free working is explained in detail in our guide UGR Value Explained. General lux reference values for all areas can be found under How Much Lux Do You Need?
Not every hall has the same requirements. The following matrix helps you quickly narrow down the right luminaire type – by ceiling height, use and protection requirement.
| Segment | Ceiling height | Recommended luminaire type | Protection rating | Lux target |
|---|---|---|---|---|
| Small workshop / automotive | 3–5 m | LED linear light, tri-proof light | IP65 | 300–500 lux |
| Warehouse (low-bay racking) | 4–7 m | UFO high bay 100–150W | IP65 | 200–300 lux |
| Warehouse (high-bay racking) | 8–14 m | Linear high bay 200–240W | IP65, IK08 | 200–300 lux (racking face) |
| Production hall | 6–12 m | UFO or linear high bay 150–240W | IP65, IK08 | 300–500 lux |
| Precision assembly / quality | 4–8 m | High bay UGR<19, Ra ≥ 90 | IP54–IP65 | 500–1,000 lux |
| Sports hall | 7–14 m | Linear high bay, UGR<22 | IP65, IK10 | 300–750 lux (DIN EN 12193) |
| Outdoor area / yard | Mast 6–12 m | LED floodlight 150–400W | IP66 | 20–100 lux |
UFO high bays are round individual luminaires with symmetrical or asymmetrical light distribution. They are particularly suited to halls with individual mounting on steel beams and ceiling heights from 5 m. The beam angle (typically 60°, 90° or 120°) determines the light cone on the floor.
Linear high bays (also LED linear lights) produce more uniform area illumination and are ideal for racking aisles, assembly lines and areas where glare from directed light must be avoided. They can be linked together to form continuous lines of light.
LED tri-proof lights are the economical choice for workshops, garages and ancillary rooms with ceiling heights up to 5 m. Our LED Tri-Proof Lights are available from IP65 and are designed for continuous operation.
A tried-and-tested approximation formula is:
Number of luminaires = (Em × area) ÷ (luminous flux per luminaire × maintenance factor × room utilisation factor)
Typical maintenance factors are 0.70–0.80 (depending on dust load and cleaning interval). The room utilisation factor (depending on reflectance values of ceiling, walls and floor) has a significant influence on the result – light-coloured surfaces can noticeably reduce the number of luminaires required.
Target: 300 lux, ceiling height 8 m, maintenance factor 0.75, luminous flux per luminaire 30,000 lm (200W LED high bay, 150 lm/W).
Number = (300 × 1,000) ÷ (30,000 × 0.75) = 300,000 ÷ 22,500 = approx. 13–14 luminaires. For a standards-compliant plan with uniformity verification, we recommend a DIALux simulation – which we offer to you free of charge.
For ceiling heights below 6 m, a beam angle of 120° is recommended to achieve broad area illumination. From 8 m mounting height, 60°–90° is more appropriate to achieve sufficient illuminance at floor level without deploying an excessive number of luminaires.
Please note: where overhead cranes, monorail systems or moving plant components are present, luminaires must be positioned so that no glare is caused to crane operators and the luminaires are mechanically protected (IK08 or higher).
Industrial environments place high demands on luminaires. Dust, moisture, oil mist and mechanical impact can quickly damage unsuitable luminaires. The IP protection degrees (in accordance with IEC 60529) and IK ratings are therefore essential planning parameters.
Our guides IP Protection Ratings Explained and IK Protection Rating Explained provide you with a complete overview. For areas at risk of explosion (e.g. spray booths, chemical stores), only ATEX Explosion-Proof LED Luminaires are permitted.
For ceiling heights of 5 to 10 m: efficient UFO high bays with up to 210 lm/W, IP65 and a 5-year guarantee – directly from our LED High Bays range.
The purchase cost is only part of the overall calculation. What matters is the Total Cost of Ownership (TCO) over 10 years – that is, investment, energy costs and maintenance expenditure combined.
Add to this the maintenance costs saved: lamp replacements at 10 m height using a cherry picker cost €150–€300 per luminaire. With 60 luminaires and a replacement cycle every 2 years, this amounts to €4,500–€9,000 per cycle – costs that are eliminated with LED. Our detailed guide on Calculating LED Payback Period shows you the complete methodology.
The BAFA funds commercial energy efficiency measures under the Federal Funding for Energy and Resource Efficiency in Industry (EEW) scheme. The KfW programme 297/298 (Federal Funding for Efficient Buildings – Non-Residential Buildings) is also relevant. Always apply for funding before placing an order – retrospective applications are not possible.
Dimmable LED high bays reduce energy consumption during break periods or when daylight is present by a further 20–40%. Common control interfaces are 0-10V, 1-10V, DALI and TRIAC. Our guide 0-10V, 1-10V & TRIAC Dimming explains the differences in practical terms.
DALI (Digital Addressable Lighting Interface, IEC 62386) enables individual control of each luminaire via a bus system – ideal for large halls with different lighting zones. 0-10V is the more cost-effective solution for simple group control.
Presence detectors and daylight sensors pay for themselves particularly quickly in warehouses with irregular pedestrian traffic. Look for IoT-capable drivers if you are planning later integration into building management systems (BMS).
Operational yards, loading bays and outdoor storage areas require robust LED floodlights with at least IP66. The illuminance required depends on the use: traffic routes 20–50 lux, working areas at loading bays 150 lux, security areas 50–100 lux.
For outdoor yards, loading bays and facades: high-performance LED floodlights with IP66, up to 180 lm/W and a 5-year guarantee.
All connection and installation work on 230V/400V systems must be carried out exclusively by approved qualified electricians. DIN VDE 0100, DGUV Regulation 3 and the 5 safety rules apply (isolate, secure against re-energisation, verify absence of voltage, earth and short-circuit, cover or barrier adjacent live parts).
For work at height (from 2 m), fall protection measures in accordance with DGUV Rule 101-004 are required. Plan maintenance access points during the installation phase – retrospective modifications to high-bay racking or crane runways are complex and costly.
Notes on the correct connection of LED luminaires can be found in our guide Connecting an LED Luminaire. This is aimed at qualified personnel and does not contain instructions for non-specialists.
The number depends on the desired illuminance (lux), ceiling height, beam angle and the reflectance of the room surfaces. As an approximation formula: Number = (Em × area) ÷ (luminous flux × maintenance factor × room utilisation factor). For a standards-compliant plan, we recommend a free DIALux simulation by our light planning team.
In most cases yes, however a direct retrofit is not always possible. Many HQL luminaires require a ballast bypass or must be replaced entirely with new LED luminaires. Check whether the existing housing can be reused or whether a complete replacement is more economical. Have the existing installation inspected by a qualified electrician before retrofitting.
A minimum of 130 lm/W is recommended, preferably 150 lm/W or more. Our high bays achieve 150–210 lm/W depending on the model – significantly more efficient than conventional HQL luminaires at 60–80 lm/W. Luminous efficacy directly influences the number of luminaires required and therefore the investment costs. More on this in our guide Lumens vs. Lumens per Watt.
Yes, provided the driver has a dimming interface. Common standards are 0-10V, 1-10V and DALI. Ensure that the driver and control unit are compatible. Not all high bays are dimmable – check the data sheet before purchasing.
Yes, provided the protection rating is appropriate. For dusty environments (woodworking, metalworking), IP65 is the minimum requirement. In the presence of oil mist or aggressive vapours, IP66 or higher is recommended, along with corrosion-resistant housings. Clean the luminaires regularly, as dust deposits can noticeably reduce luminous flux.
For general production and warehouse halls, 4000K (neutral white) has proven itself: good colour rendering, a pleasant working atmosphere, no blue tint. For quality control and precision assembly, 5000K (daylight white) with Ra ≥ 90 is recommended to reliably identify colour defects. The effect of colour temperatures is explained in our guide LED Colour Temperature.
Yes. The BAFA funds commercial energy efficiency measures under the Federal Funding for Energy and Resource Efficiency in Industry (EEW) scheme. The KfW programme 297/298 (Federal Funding for Efficient Buildings – Non-Residential Buildings) is also relevant. Always apply for funding before placing an order. Your energy consultant or our light planning team can support you in preparing the documentation.
High-quality LED high bays achieve 50,000–100,000 operating hours. The value L80B10 means: after the stated number of operating hours, at least 90% of luminaires still have 80% of their original luminous flux. At 16 hours of operation per day, 50,000 hours equates to a calculated service life of over 8 years without a lamp change.
Our light planning team will prepare a free DIALux light plan for you, including illuminance verification, luminaire selection and economic efficiency calculation – tailored specifically to your project. As a B2B direct importer, we deliver throughout the EU within 2–5 working days at prices 2–4× below branded products, with up to 5 years' guarantee.
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