Lighting Guide 006

The Lighting of Warehouses

and Storage Areas

02

Lighting Guide 006

Introduction
The aim of this Guide is to provide easy to understand principles for the
design of lighting for the widely differing types of Warehousing and
Storage areas. Special mention is made of the need to fully understand
not only the type of building with its physical structure but also the
clients methods of operation within it, so as to prepare the most suitable
and cost efficient lighting proposal.
The effective use of light should always ensure that safe and efficient
working conditions are created by using the correct choice of lamp,
luminaire and design method - coupled with the application of
suitable controls to ensure that initial and through life costs are kept
to a minimum.
Identifying the differing types of
storage facility

Are there any regulations that the lighting

design must comply with?

Before any sensible planning can take place it is

necessary to identify the various types and areas of
warehousing, their particular lighting requirements
allied to the nature of the materials being stored and
the methods used for their placement and retrieval.

The designer must ensure that the lighting meets

the requirements of the latest amendments to the
Building Regulations 2000. Parts L1 and L2 in
England and Wales and Technical Standard J12 in
Part J of the Building Standards in Scotland, together
with the appropriate Health and Safety at Work
requirements (HSG38).

The most common areas may be drawn from the

following either singly or in combination:
1 Floor storage in random locations
* Using pallets stacked to high levels or
* Pallets or loose goods at low levels, e.g. crated or
sacked produce
2 Rack storage systems at high or low levels
3 Bin storage with large or small items
4 Operated using either manual or automatic picking
5 Packing and despatch areas within the
warehouse interior
6 Loading bays.

All new build automatically falls within the

requirements of the Building Regulations and so
do all refurbished interiors where there is a need to
replace the lighting. The requirements under Part
L2 (g) and J12, are to provide a lighting system that
is energy efficient, has the opportunity for good
energy management and has been properly
commissioned. For a more detailed explanation of
these requirements see the previously published
Lighting Guide 004 Lighting requirements for Part L
of the Building Regulations for England and Wales
and Lighting Guide 005 for Scotland.

Feedback for designers and clients

Lamps and
Luminaires
In energy usage terms it should be noted that the
Building Regulations only state the minimum
requirements for compliance but, using Best Practice
design methods, as outlined in this guide, and
through the selection of the most appropriate lamp,
fitting, and controls regime, further improvements in
energy efficiencies of over 50% are readily
achievable. This offers the end user lower through
life running costs for the lighting installation and
improvements in operator efficiencies resulting in
lower total operating costs.

Select the most appropriate light source characteristics

from Table 1 below for the particular application by
giving consideration to the following questions:
Is there a suitable range of lamp wattages and hence
light packages available?
If so, are they the most efficient in energy
usage terms?
Is lamp life important?
Is access for cleaning and maintenance difficult?
Is the run-up and re-strike time critical?

Whilst not mandatory, guidance on best practice

lighting design can also be found in the Society of
Light & Lighting (CIBSE) - Code for Lighting 2002.

Is colour appearance or colour rendering important

for the application?

In addition to the general lighting, suitable Emergency

and Escape lighting will be required to EN 50 1838.
The new European Standard for Emergency lighting
which now replaces the earlier BS 5266 Pt 1: 1988.

Table 1 Typical Lamp Performance

Lamp efficacy
(lm/W)

Lamp life
(hrs)

Colour
rendering
quality and
index Ra

Colour
appearance

Run-up time
(mins)

Re-strike time
(mins)

Linear
fluorescent

75 -110*

12000
20000**

50-98
Fair to excellent

White

Immediate

Immediate

High Pressure
Sodium

70 -125*

12000
20000**

50-98
Fair to excellent

White

Immediate

Metal Halide

70 -120*

1000015000*

60-93
Good

Cool-white

* Depending upon type chosen

** Operating on High Frequency control gear

03

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Lighting Guide 006

Which lamp to use?

Which luminaire?

In general a white colour appearance light source

should be utilised. To provide an objective indication
of the colour rendering properties of a light source
the general colour-rendering index Ra is used. The
maximum value of Ra is 100. This figure decreases
with decreasing colour-rendering quality. Lamps with
a colour-rendering index lower than 80 should not
be used in interiors where people work or stay for
long periods.

The light distribution of the luminaire should be

carefully considered as it influences the distribution
of illuminance and the directional effect that will be
achieved. Additionally photometric and electrical
performance together with reliability and lamp life
will have a direct impact on the economics of
any scheme.

Within the applications covered by this Guide, where

only small to medium sized interiors are being
considered, fluorescent lamps are likely to meet most
lighting needs. However, there will be occasions when
the larger lumen packages available with High Intensity
Discharge lamps (HID) may be called for, especially in
facilities with higher ceiling heights above about 5m.
The HID lamps run-up and re-strike characteristics
should be noted as these may limit the ability to
provide the necessary lighting controls as required
under Part L of the current Building Regulations.
[See Lighting Guides 004 and 005]

The ease with which luminaires may be installed and

maintained will also have a major effect on the
through life costs of the final installation. In any
lighting design the final choice will be a combination
of several factors and the designer will have to study
these and then choose the most suitable for the
particular application.
Table 2 gives initial guidance on the suitability of the
lamp/luminaire combination but this choice may be
modified as a result of the detailed design guidance
given in the application section of this Guide.

While the older obsolescent standard white

halo-phosphate range of fluorescent lamps will just
meet most minimum requirements, from an energy
efficiency and lighting quality standpoint,
multi-phosphor lamps operating on High Frequency
Electronic control gear should always be the first choice.
Table 2
Typical mounting height in metres
Lamp and luminaire

Comments

Minimum

Maximum

Fluorescent luminaire
with Trough reflector

2.5

Rack reflector

12

Discharge lamps
[any type 150/250w]
in Low Bay reflector

Usually bare lamp, could cause glare to

fork lift truck drivers when accessing
high stacked pallets

Discharge lamps
[any type 250/400w] in
dispersive High Bay reflector

12

400w lamps likely to be too

large a lumen package for
other than open space areas

May be difficult to maintain

at heights above 5m

Principal light fitting types

Principal light
fitting types
Special application needs

1 Fluorescent Wide Dispersive Reflector

Whilst the installation of standard luminaries will

often meet most needs, consideration should be
given to any extreme environmental conditions
which might effect either the performance, the life
of the installation or the safety of the operatives.
For example, where there is any likelihood of impact
to the luminaires, the fitting of wire guards should be
considered. Fully enclosed luminaires may be needed
in applications where food stuffs are stored or where
the danger of broken glass is critical.
When using Metal Halide lamps care must be
exercised, if open reflector luminaires are chosen, that
the appropriate double jacketed lamp is specified.
Special attention must be given to cold stores
because of the low temperatures involved. The most
common problems that will be encountered are with
fluorescent lamps on starting, low light output and
icing up. Specially developed fully enclosed
luminaires are available for these applications.
In general, it is better to use a High Pressure Sodium
light source as these lamps are relatively unaffected
by temperatures as low as 30oC.
Note that some instant light must be provided for
safety reasons in case the sodium lamps are
extinguished for any reason.

Suitable for a wide range of general

lighting applications
Spacing to height ratio is the distance between the
centres of adjacent fittings divided by their height
above the working or reference plane
Wide photometric distributions giving spacing to
height ratios of 1.5 1.75 will minimise shadowing
Low surface brightness for both lamps and reflectors
is a major benefit to operators in reducing glare
May allow for some upward light to illuminate the
roof so reducing discomfort to the operator of fork
lift trucks when stacking at high levels
Instant light, at switch-on and re-strike
Can be dimmed to 5% output as part of an energy
management or daylight linked system, using HF
electronic ballasts
Wire guards are available if required.

05

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Lighting Guide 006

2 Fluorescent Narrow Distribution with

Polished Aluminum Reflector

3 Discharge High Pressure Sodium [HPS] and

Metal Halide[MH]

Particularly suited for use in narrow aisled

locations when run parallel with aisle

Low Bay box type luminaires can be used at 5m

mounting heights and above

Tight and precise optical control allowing for

use at higher mounting heights (>5m)

Available for either 150 or 250w High Pressure

Sodium[HPS] or Metal Halide lamps[MH]

Typical spacing to height ratios 0.75 1.0

High optical performance with wide transverse

light distributions

Instant light, at switch-on and at re-strike

Can be dimmed to 5% output as part of an energy
management system, using HF electronic ballasts
Wire guards are available if required.

Distribution suitable for lighting up and down long

and narrow aisled stores
Run up and re-strike times subject to chosen lamp
[See table 1]
Liable to increase operator glare due to high
brightness of lamp
HPS versions can give very long lamp lives
typically 25,000 hrs
Availability of a wide range of accessories including
wire guards, glare control louvers and clear visors
Fully sealed versions available for use in specialized
locations such as food stores and cold rooms.

Selecting the right illuminance

4 Low Bay Round Reflector

Generally used at higher mounting heights above

5m. Only versions with wide distributions are really
suitable for these applications
Available for 250 400w lamps either HPS or MH
Run up and re-strike times subject to chosen lamp
[See table 1]
Liable to increase operator discomfort due to high
brightness of lamp
HPS versions can give very long lamp lives
typically 25,000 hrs
Prismatic versions allow some upward light to roof,
reducing the contrast between the source and
background helps to reduce operator glare

Can be used in a similar way to box types but

having a circular distribution it is also suitable
for general lighting of open areas. With care,
can be used in a wide aisle location.

5 High Bay Reflector for HPS and MH Lamps

Availability of a wide range of accessories including

wire guards, glare control louvres and clear visors.

Selecting the
right illuminance
The recommendations contained within the Society
of Light and Lighting, Code Lighting 2002 [CIBSE],
divides and separates functions according to the
difficulty of the visual tasks. [See table 3]

High Bay reflectors in aluminium, prismatic glass

or plastic. Can have a wide range of photometric
distributions ranging from very narrow through
medium to widespread.

Whilst the defined areas are easily identified it must

be remembered that there will often be additional
functions carried out in other parts of the same
warehouse that will require the provision of
additional localised lighting. Such areas may include
issuing counters, packing and despatch benches as
well as associated loading bays.

07

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Lighting Guide 006

Table 3 Illuminance recommendations

Maintained Illuminance (Lux)

Minimum Colour Rendering (Ra)

Store and stockrooms

100

60

Dispatch packing handling areas

300

60

Automatic high rack stores

unmanned gangways

20

40

Automatic high rack stores

manned gangways

150

60

Automatic high rack stores

control stations

150

60

Loading bays

150

60

Forms of control
Lighting controls

Control inputs

Control systems are an important part of any

lighting installation. They can take many forms,
varying from the simple wall switch to sophisticated
microprocessor-controlled building management
systems. Whatever the method used, the aim is to
ensure that the lighting is operating only when
required and that, when on, it is operating in the
required state. Control systems vary the light output
of the installation, either by switching or by
controlling the output of the lamps and so reducing
energy use.

The four basic methods of lighting control are:

time based
daylight linked
occupancy linked
localised switching.

An essential aim of lighting controls is to encourage

the maximum use of daylight where available and to
avoid the unnecessary use of electric lighting during
times when sufficient daylight is present.

Control devices include manual switches, infrared

transmitters and detectors, time clocks, PIR detectors
and light sensors. They may be used individually or in
combination to optimize their benefits.
In principle, all light sources can be switched.
However, not all lamps provide their full light output
instantaneously - the vast majority of discharge
lamps have a run-up time and some an extended
re-strike time. (See table 1 for suitability)
Most fluorescent lamps can generally be dimmed
down to 5% using High Frequency Regulating
electronic ballasts whilst High Intensity Discharge

Forms of control

09

Decision chart
lamps are less easy to dim. In general, it is not
recommended to dim Metal Halide lamps due to
severe colour distortion. However, it is possible to
dim High Pressure Sodium lamps down to about
50% output.
In most practical applications the electrical
contractor may have little or no control over the
buildings daylight provision. However, it is important
that, before any lighting scheme is prepared, an
attempt is made to establish the Daylight Factor for
the interior. (Daylight Factor is the illuminance at a
point internally expressed as a percentage of the
illuminance under an unobstructed overcast sky).
This information should be obtainable from the
Architect or from a study of the roof glazing area
related to the total roof area.
As a guide when the average Daylight Factor exceeds
5%, natural lighting should be adequate for most
purposes during daylight hours. However, with an
average Daylight Factor of less than 2% permanent
supplementary electric lighting will be required.
Between these two extremes there exists scope for
considerable running cost savings of between 20
and 30% just by the installation of suitable daylight
linked photocell controls switching off or dimming
the lighting according to the amount of daylight
present.

yes

IS DAYLIGHT
AVAILABLE?

no

PHOTOCELL LINK

yes

CONTINUOUS OR
FREQUENT
OCCUPANCY?

no

DIRECT SWITCHING

yes

REGULAR SHIFT
PATTERNS

TIME CLOCK

no
LIMITED ACCESS
ROUTE INTO
AREA

no
LIMITED ACCESS
ROUTE INTO
AREA

no
yes
MAJOR OBSTRUCTIONS
& MOVING PLANT

no
PRESENCE
DETECTOR

Choosing the right controls

The development of a controls strategy for any
installation will require answers to a range of
physical and operational criteria. Some of which will
have to be obtained from the client and others from
a study of the actual building, if built, or from the
roof plans, if not. The following flow chart takes the
designer through a logical sequence of questions and
answers leading to the selection of the most suitable
controls regime for a particular installation.
Specific advice for individual applications is
contained in the relevant application section,
see page opposite.

Time based
A timer control system may switch the lighting
installation on or off at programmed times
according to the work pattern. Time control may
be derived from a variety of devices ranging from
simple electro/mechanical switches through to full
computer based building management systems.
It is important to include for local override so that
the lighting can be restored if the lighting is needed
out of normal planned operating hours. Sequenced
switching-off of the lighting by stages will prevent
the dangers created by instant blackout thus allowing
time for operatives to override the time off signals.

10

Lighting Guide 006

Daylight linked
Photo-electric daylight
linked controls can be used
to switch on/off High
Pressure Discharge lamps.
They can also be used to
switch on/off or gradually
dim up/down most
fluorescent lamps.
Photo-electric switching which causes a sudden and
noticeable change in lighting levels is likely to lead
to user complaints unless the area is well day lit.
However, photo-electric dimming is unobtrusive.
The dimming controller should be set so that the
combination of daylight and electric lighting remains
constant at the design illumination level.
The energy saving potential of dimming control is far
greater than for simple photo-electric switching and
offers the greater through life running cost reduction.

Occupancy linked
Lighting linked to occupancy, or more appropriately
occupancy patterns, can make considerable savings
in energy usage.

Occupancy detector
at end of aisles

Occupancy detectors
at centre of aisles

This form of control must take into account the run up and
re-strike characteristics of the lamps. (See table 1)

Occupancy detectors are used to detect the presence

of people and to control the lighting accordingly.
These can be acoustic, infrared or microwave devices.
They will enable the lighting when occupancy is
detected and turn it off again once they fail to
detect any occupancy within their zone of sensitivity.
Inbuilt time delay (adjustable up to 30 minutes) is
necessary to prevent inappropriate off switching if
the occupant remains still or quiet before actually
leaving the controlled area.

Long range microwave

detector with effective
range 30 to 50m

PIR detector effective

range up to 12m

This form of control is especially suited to the

detection of an approaching fork lift truck or an
individual operative moving into a warehouse aisle.
Predetermined delay times should be built into the
system to avoid excessive switching which can
seriously shorten lamp life, especially if switch start
fluorescent circuits are utilized. However, switching
or dimming of fluorescent lamps, when operated on
either dimming or preheat electronic ballasts, has no
detrimental effect on lamp life.
Localised switching
Bulk or localised switching is important where only
part of a large space requires the lighting to be
switched on, either because parts are unoccupied
or that daylight is adequate. The manual control of
lighting is to be generally discouraged as it offers
no automatic energy saving potential, relying as it
does on manual intervention to switch off
unnecessary lighting.

Application design

Application design
How to select the most suitable
lighting solution
In open areas with ceiling height up to 5m, with
random storage generally at or near floor level, it is
necessary to avoid darks shadows. Also, the provision
of light on all vertical surfaces is important allowing
for the reading of labels and other marks.
The ideal solution is to use closely spaced overhead
arrays of fluorescent slotted top white enamelled
reflector luminaires or lower power discharge
luminaires [Max 250w] with wide distributions.
The arrays should not exceed the spacing to height
ratios for the chosen luminaires.

Warning If a High Pressure Discharge option is

selected, the temptation to use a smaller number
of higher wattage lamps on maximum spacing must
be resisted. Whilst it is possible to achieve the same
calculated illuminance at floor level using fewer
lamps, the resultant installation will produce heavy
shadows, poor vertical illuminance with little light
between luminaires at heights above floor level.

Installation using 2 x 400w HP Discharge lamps

Fittings over-spaced for
the application giving
little light above floor
level, heavy shadows
created and poor
vertical illuminance

Superior lighting design using 3 x 250w HP Discharge lamps

Fittings spaced so as to
light to the top of the
pallet stack, thus giving
good vertical
illuminance on all
surfaces with no heavy
shadows

11

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Lighting Guide 006

Random high level pallet storage

With the storage and accurate manipulation of
pallets at high levels, care must be exercised if the
lighting is not to cause difficulty in seeing and
potentially dangerous conditions for the fork lift
truck drivers. They will frequently be looking up
towards the lights and can experience excessive
glare produced by over-bright luminaires.
The preferred solution is to use fluorescent luminaires
with an upward lighting component which will help
reduce the contrast between the lights and the ceiling,
especially if the roof has a high surface reflectance

12m

Rack

Aisle

Traditional
Twin Trough reflector

Rack

Aisle

Rack

Narrow transverse
distribution luminaire

The use of HID lamps and luminaires could be

considered if the storage area is infrequently
occupied or goods are not stacked at high levels.

Rack storage at both low and high levels

Bin storage - Manual selection

In high palletised narrow aisle racking areas, the main

problem is to get the required illuminance at floor
level between the racks without there being too much
light at the rack tops. Again, the creation of difficult
and possibly dangerous seeing conditions must be
avoided. In areas where the ceiling height is up to12m,
it is good practice to light these narrow aisles with
runs of nearly continuous electronically ballasted
fluorescent luminaires using either 1.5m 58w or
1.8m 70w T8 26mm tri-phosphor fluorescent lamps.

Bin storage areas may be divided into two general

types. The first is where the bin racks are fixed and
secondly when the racks are movable. In both cases,
the important element is to enable light to penetrate
the depth of the bin and, to achieve this, near
continuous fluorescent luminaires should be
mounted just above bin height and forward of the
bin front edge.

Luminaires with narrow transverse distributions

should be arranged along the aisles (See fig above).
If conventional dispersive reflectors were to be utilised,
with their wide transverse distributions, little light
would reach ground level whilst the top of the racks
would be brightly illuminated.

Problems will be encountered if the bin racks are

infinitely movable- sometimes referred to as
concertina storage mechanisms - as they may be
very close together. Here a compromise solution has
to be adopted using continuous runs of fluorescent.
Dispersive reflector luminaires should again be used
but, in these situations, they have to be run
at 90 degrees to the aisles. The spacing between
rows becomes critical and has to be related
to the mounting height above the tops of the bin
racks. With conventional dispersive reflectors the
spacing between rows should not exceed 1.5 times
the height above the rack tops.

Application design

13

Spacing

Fluorescent luminaires
mounted on trunking.
Spacing should not
exceed - 1.5 x Ht
Cut-off
angle

Ht
Cut-off
angle

As many bays are external, luminaires that will

operate at lower temperatures as well resisting the
ingress of moisture must be used.
The following diagrams illustrate the lighting
techniques for the most common types of loading
bay. In bays with canopies at 3-6m above floor level
enclosed fluorescent luminaires should be mounted
to the underside of the canopy and positioned to
illuminate both sides of the vehicles.

Luminaire positioning above racking

It will be appreciated that this compromise

method of lighting could be very wasteful of energy,
in that a high proportion of the light produced will
be wasted, lighting the tops of the movable racks.
A control system that provides for selective
switching could help reduce this waste.

For canopies higher than 6m as well fluorescent

lamps, High Pressure Discharge lamps may be used.
The luminaires should be general dispersive reflector
units mounted to the underside of the canopy but so
positioned as to illuminate not only the loading bay
itself but also its leading edge. Where fully enclosed
box vans are used additional floodlights may need
to be positioned so as to throw light deep into the
van itself.

Bin storage - Automatic operation

In fully unmanned automated warehouses no
specialist lighting is needed, save that a general
illuminance of 20 lux should be provided at floor
level to allow for safe access. For maintenance
purposes, supplementary lighting will be required.
This may take the form of general lighting provision
which under normal operating conditions is switched
off or could be provided by portable lighting units
positioned as required.
If the warehouse has manned gangways and/or a
rack control station, a maintained illuminance of 150
lux at floor level will be required using the design
methods previously covered.

Loading bays
The lighting techniques employed in the lighting of
loading bays will depend upon their physical
structure. For all of these areas the lighting must be
designed to create a safe working environment as
well as an efficient one.

Peek intensity
below drivers sight

Floodlighting luminaires for high canopy loading bays

Floodlight for
lighting inside
of a van used
only when vehicle
is parked

14

Lighting Guide 006

Can I claim ECAs on my

spending on lighting?
A business can claim 100% first-year Enhanced
Capital Allowances (ECAs) on its investment in
designated energy saving plant and machinery.
The qualifying technologies include lighting.
There are two key tests that need to be satisfied
before a claim to the allowances can be made on
expenditure on lighting.
The lighting must qualify for capital allowances it must be "plant or machinery"
The lighting must be qualifying "energy saving
lighting".

Lighting is not "machinery", so expenditure can

qualify for capital allowances only if the lighting is
"plant". Broadly speaking, "plant" is the apparatus
with which a trader carries on his or her business,
as opposed to the premises from which the trade is
carried. The Inland Revenue has published notes on
when lighting can qualify for capital allowances as
part of its guidance on the ECA scheme. The guidance
is available on the Inland Revenue's website
www.inlandrevenue.gov.uk.
"Energy saving lighting" is that which conforms to
the standards published in the Energy Technology
List published on the ECA website www.eca.gov.uk.

Contact addresses

Further
information
Action Energy helpline 0800 58 57 94 or visit
www.actionenergy.org.uk
Installers Lighting Guide 001 Electric Lighting of
Small Offices and Similar Spaces
Installers Lighting Guide 002 Lighting for Small Shops
Installers Lighting Guide 003 Exterior Lighting for
Small Premises
Installers Lighting Guide 004 Lighting Requirements
for Part L of the Building Regulations [England
and Wales]
Installers Lighting Guide 005 Lighting Requirements
for Meeting the Technical Standards for Compliance
within the Building Standards [Scotland]
Good Practice Guide160 Lighting Controls
A Guide for Designers, Installers and Users

Good Practice Guide 199 Energy Efficient Lighting

A Guide for Installers
BRE Publications
Available from CRC Limited (Tel 020 7505 6622)
BRE report. Energy efficient lighting Part L of the
Building Regulations [ E & W ] explained, CRC 2001
Society of Light and Lighting
Code of Lighting 2002

Contact
Addresses
Electrical Contractors Association (ECA),
34 Palace Court,
London W2 4HY
The Installers Guide to Lighting Design
Electrical Distributors Association (EDA),
Union House, Eridge Rd,
Tunbridge Wells,
Kent TN4 8HF
Tel 01892 619990 Fax 01892 619991
Society of Light and Lighting,
222 Balham High Road,
London SW12 9BS
Tel 020 8675 5211 Fax 020 8675 6554
http:// www.cibse.org
Code for Lighting (2002)
Institution of Lighting Engineers,
Lennox House,
Rugby CV21 2DZ
Tel 01788 576492 Fax 01788 540145
Lighting Industry Federation (LIF),
207 Balham High Road, London SW17 7BQ
Fax 020 8673 5880
E-mail info@lif.co.uk
Select
The Walled Garden,
Bush Estate, Midlothian EH26 OSB
Tel 0131 445 5577 Fax 0131 445 5548
E-mail admin@select.org.uk

Action Energy would like to acknowledge the support of the Society of Light and Lighting and Thorn Lighting
who have supplied the images and diagrams used within this Guide.

15

Tel 0800 58 57 94

www.actionenergy.org.uk
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