Facility managers, warehouse operators, and school administrators often face a familiar dilemma when it comes to lighting upgrades: Should they retrofit their existing high bay lighting or replace it entirely with new fixtures? It’s not just a question of cost — there’s a lot more to consider, from energy efficiency to long-term performance.
So, what’s the right choice for your space? Let’s break down the pros and cons of both options and explore the key factors that can help you make an informed decision.
The Benefits of High Bay LED Lighting for Commercial Spaces
High bay lighting is found in a variety of spaces — gyms, warehouses, and industrial facilities — all with different lighting requirements. Deciding whether to retrofit or replace legacy lighting depends heavily on the specific application. Are you lighting up a gymnasium where illumination needs to meet UIL Standards for Competition Gyms, or lighting requirements to broadcast televised games, or a warehouse where safety and task accuracy are key?
Every situation is different. The type of space, the height of the ceiling, the ambient temperature, and the required light output all factor into whether retrofitting or replacing is the best option.
Why High Bay Retrofit Options Appeal to Facility Managers
Retrofitting is often an appealing choice for facility managers and decision-makers, offering several benefits that make it a practical solution for many spaces. Some key reasons include:
- Cost savings: Retrofitting is generally more affordable than replacing fixtures entirely, allowing businesses to upgrade their lighting without a large upfront investment.
- Minimal disruption: Because retrofitting involves upgrading existing fixtures, it can be done quickly and with less interference in daily operations, making it ideal for facilities that need to remain functional during the process.
- Sustainability: By reusing existing fixtures, retrofitting helps reduce waste and supports sustainability goals, making it an environmentally friendly option.
But as we’re about to see, retrofitting can be less attractive in practice for high bay applications.
Case Study: Why Retrofitting Failed in a School Gym
Take our client, a small school in Roswell, New Mexico. They faced a common issue with the aging high bay lighting system in their gymnasium. The space was originally outfitted with 400-watt metal halide fixtures, a popular choice for high ceilings. The lights performed well when first installed, but their output began to decline sharply over time. After just 2.5 years, they lost up to 50% of their brightness. The constant need to replace the bulbs and ballasts was becoming a drain on maintenance resources and energy budgets. To solve the problem, the school decided to retrofit the fixtures with what seemed like an energy-efficient solution: screw-based “corncob” LED lamps and by-passing the HID ballast.
At first, retrofitting the gym’s existing fixtures with corncob LEDs appeared to be a smart and cost-effective solution. These bulbs are designed to screw into existing sockets, making installation straightforward and cost-effective.
But the school quickly ran into several issues with the corncob LEDs:
- Inconsistent light distribution: The reflective design of the old metal halide fixtures was intended for a small High Intensity Discharge (HID) arc tube, but the larger corncob LEDs scattered light in unintended directions, leading to uneven lighting across the gym.
- Inadequate lighting for sports activities: Instead of focusing light downward, which is crucial for activities like basketball, the corncob LEDs provided insufficient and inconsistent illumination on the court.
- Overheating due to high ambient temperatures: The gym's high ceilings and desert heat caused the corncob LEDs to overheat, which led to premature failures.
- Frequent replacements: The school found themselves replacing the retrofitted lights much sooner than expected, negating any potential cost savings from the initial retrofit.
Frustrated, they turned to Litetronics for help. After reviewing the gym’s conditions—high ceilings, excessive heat, and the need for uniform light distribution, we recommended replacing the corncob LEDs with new, high-efficiency LED fixtures designed specifically for high-heat environments. These fixtures not only solved the overheating issue but also provided better, more focused light coverage, meeting the gym’s foot-candle requirements for both recreational and competition events.
Where Retrofitting Works Best
Retrofitting isn’t always a bad idea. It can actually be a good choice in certain applications, including:
- Lower Ceiling Applications: Retrofitting makes sense in Low-height warehouse aisles, stock bin aisles, locker rooms, task lights, offices, classrooms, and corridors. These environments typically don’t require high-output lighting, and retrofitting can achieve the necessary brightness while reducing energy consumption.
- Healthcare Environments: In spaces like hospitals or dental offices, retrofitting offers a way to upgrade lighting without opening up the ceiling, which can distribute dust and raise contamination concerns.
If you’re looking for a retrofit solution in lower ceiling environments, consider Litetronics’ LED Strip Retrofit Kit. They’re an easy, cost-effective option that can be installed without major disruption to your space.
Challenges of Retrofitting High Bay Lighting
But in high bay settings — like gyms or warehouses — retrofitting often isn’t your best bet. High ceilings demand higher light output, and retrofitting with LED tubes or kits may not replicate the photometric performance of traditional fixtures. In some cases, retrofitting can lead to scattered light distribution, creating safety concerns or visibility issues.
Replacing High Bay Lighting with New Fixtures
If your facility has high ceilings or requires high-output lighting, replacing your fixtures with new LED high bay lighting is often the better choice. Modern LED fixtures offer significant advantages in terms of efficiency, durability, and light quality.
Benefits of Replacing Fixtures
- Improved Energy Efficiency: New LED fixtures are designed to maximize energy savings without compromising on brightness.
- Enhanced Light Quality: High bay fixtures are engineered to provide optimal light distribution at higher mounting heights, reducing glare and improving visibility.
- Longer Lifespan: Unlike retrofitting, which can lead to failures due to improper heat management, new LED fixtures are built to withstand extreme temperatures and ensure consistent performance.
Making the Right Choice for Your Space
So, how do you decide whether to retrofit or replace your high bay lighting? Here are a few key factors to consider:
- Budget: Retrofitting can be a more affordable upfront solution, but replacing fixtures often provides better long-term value.
- Energy Savings: If energy efficiency is your top priority, replacing old fixtures with new LED systems will offer greater savings.
- Light Quality: In high-demand environments like gyms or warehouses, maintaining consistent light output is crucial for safety and productivity.
- Ambient Conditions: For spaces with extreme temperatures, such as warehouses or manufacturing facilities, new LED fixtures designed for those conditions will perform better than retrofitted solutions.
Ultimately, your decision should align with your facility’s unique needs. In lower ceiling spaces like offices or classrooms, retrofitting can offer a quick, cost-effective solution. But in high bay applications, replacing the entire fixture is probably your best bet. It ensures better performance, longer lifespan, and fewer maintenance headaches.
At Litetronics, we understand the importance of making the right lighting decision. Whether you’re retrofitting existing fixtures or installing new high bay LED lighting, we offer solutions tailored to your needs.
Our wide range of high bay LED fixtures is designed for optimal performance in even the most demanding environments, providing energy-efficient, high-quality lighting for your facility. And for those looking to retrofit, we offer solutions that deliver on performance while keeping costs down.
For more insights into optimizing lighting in Industrial Facilities, download our guide Your Guide to Selling Industrial Lighting
And, for educational facilities and gyms, download our Guide to School Lighting and learn how to create a brighter, more efficient environment.
