High Bay Lighting New Design and Retrofit with Installation

  • Facility Lighting upgrades such as warehouse, manufacturing, storage, shipping, etc. 
  • Annual Energy Savings kWh and Amps
  • Annual Dollar Savings Calculation
  • Return on Investment
  • Photometrics Engineering

Types of Lighting Fixtures

  • T5HO 
  • T8
  • LED
  • Induction - ceiling, wall and pole mount
  • Pulse Start Metal Halide - ceiling, wall and pole mount
  • Enclosed and Gasketed - waterproof
  • Explosion Proof Class I Division I

Benefits of T5HO Achieve up to an 80% energy reduction on lighting electrical use

  • Maintenance Reduction
  • Lamp life and specifications
  • No One Size fits all
  • Occupancy Sensors
  • Instant On Technology
  • Temperature/Pressure difference
  • Fire hazard
  • Dirt build up

Facility Lighting Audit

CRAFT ELECTRIC sends a PROJECT MANAGER to examine your facility’s electric lighting systems and evaluate how energy consumption can be reduced. The energy audit provides estimates for upgrading building lighting to achieve maximum energy savings and pollution reduction by lowering watts per square-foot and still maintaining adequate light levels for the task or area. Virtually all facilities can benefit from a lighting upgrade or retrofit. The audit is the first step. The audit report gives management the information needed to determine further action, cost effectiveness, return on investment and design.

Smart design is a priority. There is no guessing. Everything is backed up with sound engineering and math. There is no one size fits all when it comes to industrial lighting systems.

Annual Dollar Savings 

  • We count your current lighting fixtures.
  • We determine your current fixture wattage.
  • 400 watt bulb plus 65 watt ballast = 465 watts
  • We calculate your system wattage:
  • Number of fixtures times fixture wattage =  Total system demand.
  • We calculate annual number of hours your lights are on. This is provided by the facility or plant manager.
  • We look at your electric bill to find your cost per kilo/watt hour. $kWh.
  • This information gives us your total current cost of the facility lighting system. (System demand X Annual Hours X $kwh)
  • We determine your new annual kWh system usage based on the wattage of the energy efficient lighting fixtures.
  • Compare the current cost of energy consumption to proposed future consumption with same operating hours.


Return on Investment

Once the annual savings is calculated, that is compared to the cost of the project.

Photometrics Engineering

What is a photometric layout? A chart or model of light levels generated by an array of fixtures or lamps usually computer generated.

What is a photometric layout used for?

To determine the amount of foot-candles delivered from the fixture’s mounted position to the work area or work floor. By reproducing the spread of the facility lighting fixtures as it appears as a grid and the height of the fixture mounting, we control the amount of foot-candles delivered to the working area or floor. The facility lighting grid is fixture spacing row-to-row and column-to-column. We calculate an overlap of the lighting and increase or decrease number of fixtures or number of lamps to achieve desired foot-candles readings.

Maintenance Reduction Lamp Life

  Lamp  Hours  Results:

  LED by 50,000 hrs, 95% of the lumens are maintained. 

  T5HOby 35,000 hrs, 94% of the lumens are maintained.

  Metal Halide by 10,000 hrs, 40% of the lumens are lost.

No One Size fits all

LED lighting is less expensive than ever and even more efficient. We have a broad product line to best fit your budget, look and function.

Our T5HO precision high bay fluorescent fixtures combine highly efficient T5 lamps and proprietary reflectors in a variety of beam spreads. This variety of beam widths allows for focused light in applicationmounting heights ranging from 15’ to over 100’. Our state of the arttechnology increases overall efficiency by producing a superior fixture while reducing waste, providing light where it is needed most.

Our various lamp configurations are designed to deliver improved lighting and significant savings. Our manufacturers High Bay fluorescent fixtures combine highly efficient T5 lamps and proprietary reflectors in a variety of beam spreads.

Benefits of T5 High Bay Fixtures

For many years, the standard for lighting high bay applications such as warehouses, industrial and manufacturing facilities has been the 400 Watt Metal Halide fixture. Advances in ballast technology and the introduction of the T5 High Output Linear Fluorescent lamp have led to many new luminaries that are targeted specifically for high bay applications. The following article details the many benefits that the T5HO high bay fixture offers over traditional 400 Watt Metal Halide high bays.

Energy Efficiency

With the rising cost of energy, facilities and operations managers are doing everything possible to lower total power consumption. One of the main reasons many companies turn to T5 HO high bay fixtures when retrofitting their lighting system is the T5’s ability to provide better light while consuming much less energy than traditional 400 Watt metal halide fixtures. T5 HO fluorescent lamps consume 54 Watts of power and output up to 5,000 lumens per lamp. Typical 4-lamp fixtures consume a total of 23 Watts vs. the 465 Watts that a 400 Watt Metal Halide consumes. In most cases, maintained foot candle readings are almost always better per energy dollars spent.

Lumen Maintenance

Westinghouse T5HO lamps are rated for 35,000 hours compared to metal halide or high-pressure sodium rated for 20,00 hours. Important consideration is lamp depreciation and light output as the lamps age. T5 fluorescent lamps only lose 5-6% of their lumen output between the rated initial spec and the mean spec. By contrast, Metal Halide lamps can lose as much as 55% depreciation of lumen output during the same time period. This difference becomes more pronounced as the lamps continue to age. Also, metal halide loses as much as 40% of useful lumen output by the first 10,000 hours.

No Strike/Re-strike Delay

HID lamps require some time to turn on. This is called the strike time. If the lamps have been on for some time and power is cut off, they would also need time to re-strike. The rated time for re-strike is 19.4 minutes. In areas where electricity distribution is interrupted more frequently (storms and demand spike) this could cause significant down time if employees are instructed not to work during lights out. Fluorescent lamps however, turn back on instantly without affecting the rated life of the lamp. Employees are able to return to work as soon as power is available. In areas when the power interruption is only momentary, the difference in lighting is either continuous working or an unscheduled 20-minute work stoppage.

Instant-On also allows these lighting fixtures to be used with occupancy sensors, photo cells and advanced lighting control systems that can further reduce operating costs by turning off the fixture when not in use. Modern T5 ballasts also allow for multiple switch legs that can individually control the pairs of lamps in a fixture. These can be wired into separate circuits or control systems to allow for dimming options.

More Usable Light

A linear fluorescent lamp shines light out radically in every direction from the center of the tube. Light that is cast out of the top of the lamp towards the fixture bounces off of the reflector and comes back towards the work plane. For larger T12 and T8 lamps, the size of the tube prevents most of this light from reaching the work plane because it bounces back to the tube. Since T5 tubes are extremely thin (only 5/8” diameter), more light can exit the fixture. This leads to more efficient fixtures and less shadows.

Reflector Engineering

Westinghouse reflectors used in T5HO fixtures are designed to the thousandth of an inch for facet length. To make accurate reflectors you need to minimize diffusion. Diffusion is when light scatters randomly in a material. Westinghouse uses specular material that not only highly reflective, but is also minimally diffuse.

Better Color Rendition

Color rendition index (CRI) is the measure of the ability of a light source to reproduce the colors of various objects faithfully in comparison with an ideal or natural light source. T5 lamps have a CRI of 85 while metal halide lamps, on the other hand, have a CRI of 65-70. The lower CRI negatively impacts visual acuity and can strain the eye. The following table provides a comparison of the CRI for several light sources.


Color Temperature

Modern fluorescent lamps are available in a wide variety of color temperatures. These range from 3000K to 6500K. Specialty lamps extend the spectrum even more to suit specific purposes.

Consistent Color Output

Fluorescent lamps maintain a more uniform color output throughout their life. Metal Halide or other HID sources can have their output color shift as the lamps age.

Heat and Pressure

Fluorescent lamps operate 200f and under very little pressure. Metalhalide lamps operate at 2,000f and 90 psi of pressure. This extreme heat and constant pressure wears the lamp’s integrity down overtime. If the lamp is kept in continuous service 24 hours a day 7 days a week, the pressure and heat can cause fatigue leading to explosion as the brittle lamp glass can no longer contain the 90 psi of pressure. The resulting explosion scatters 2,000f glass fragments. Any combustible material below is at risk and a potential fire is possible.

Occupancy Sensor - nothing saves energy like lights out.

High-Bay Fixture Mount Occupancy Sensor, (360 degree High Bay (25-40’) lens, 360 degree Low Bay (8-25’) lens and Aisle way lens included), 

Occupancy Sensor have practical application in many facilities especially warehouse, distribution centers, and storage areas of production facilites. With occupancy sensors, large facilities have seen lighting energy reductions of up to 80%. Never is an area left in complete darkness where employees are present. This occupancy sensors combined with instant on technology are suitable for use with fork truck traffic. The sensors will turn on lights while picking up either a heat signature or motion signature from up to 40 feet away. This is enough time to get the lights on before the fork truck is close. Safety is never sacrificed for energy efficiency .



Lighting accounts for approximately 20% of all electricity use in the United States, and about 40% of energy consumption in the commercial building sector. Much of that energy is wasted, resulting in higher than necessary utility bills and carbon emissions. However, lighting retrofits can reduce energy costs by as much as 50% in some buildings, thanks to rapidly evolving technology. The challenge during a lighting retrofit is to achieve significant energy savings while maintaining a safe, well-lit environment that enhances the productivity of building occupants. Fortunately, the newer lighting technology provides the same or better light levels as older equipment. It also reduces glare, produces more natural-looking light, and does not flicker or hum. Here are some other benefits:

• Reduced maintenance costs due to lamps and ballasts that don’t need to be replaced as frequently

• A positive impact on the environment by decreasing carbon emissions

• In a work environment, better lighting improves employee productivity, quality control, safety and security

• In a learning environment, better lighting improves classroom performance


Energy-Saving Opportunities

It is time to retrofit your lights when:

1. You have obsolete technology that no longer meets Federal energy efficiency standards. Older technology consumes a significant amount of energy, and much of it contains hazardous substances like mercury and PCBs.

2. You have older high-bay or outdoor fixtures that require costly maintenance. Repairing a single post top light entails at least two hours of labor, a bucket truck and other equipment. This is a fixed cost that can run in the millions of dollars, a daunting burden for facilities facing tight operating budgets.

3. You have areas where the lights are often left on while the space is unoccupied. This problem can be eliminated by installing occupancy sensors, devices that are integrated into the lighting circuit and turn the lights off when the space is left unoccupied for a predetermined period of time.

4. During daylight hours, there is enough ambient light in some rooms to render the electric lights unnecessary. This can be addressed with a daylight harvesting system, which uses photo sensors to detect light levels in a room and adjust the level of artificial lighting accordingly.

5. Your fixtures have lamps with different colors, or your lights flicker, buzz and cast uneven light throughout your facility. These are common problems that detract from the aesthetics of a space and even safety levels, depending on what function the space serves. In offices, glare can also be a problem, leading to fatigue and eyestrain. All this can easily be corrected with a lighting retrofit.