LED high bay installation in the UK

Polaris Light surveys, designs, supplies and installs LED high bay lighting for warehouses, distribution centres and factories across the UK. This page explains who it is for, how a project runs from survey to switch-on, what affects cost and timing, and what to expect on compliance and warranty.

Who LED high bay installation is for

• Warehouses and distribution centres with racking aisles, picking areas, marshalling zones and loading bays.
• Factories and manufacturing sites with production halls, assembly lines and workshops.
• Cold stores and food sites, where fittings need to cope with low temperatures, washdown or humidity. For wet or corrosive areas we use PS-CORROSION.
• Hazardous areas, where ATEX rated fittings such as PS-ATEX-HIGHBAY are needed.

Typical projects replace metal halide, sodium or fluorescent high bays with LED, often with presence and daylight sensors so empty zones dim or switch off.

How an installation project runs

1. Site survey

We visit the site and record the building, mounting heights, racking layout, existing fittings, circuits, controls and access. We also note how the site operates: shift patterns, busy periods and areas that cannot be closed.

2. DIALux lighting design

Before any project we can produce a DIALux 3D simulation that calculates the lux levels our fittings will give in each area. The design is checked against the recommended levels in BS EN 12464-1, for example on racking aisles and rack faces. See our guide to warehouse racking aisle lux levels.

3. Proposal and quote

You receive a proposal with the fitting schedule, the lighting design, the installation plan and the expected energy saving. Savings are shown as an estimate based on your own fittings, hours and tariff.

4. Installation planned around your operations

Installation can be carried out out of hours, at nights or weekends, or in phases zone by zone, so the warehouse or production line keeps running. The plan covers which areas are worked on when, and how they are kept safe.

5. Access equipment

High bays are often mounted at height above racking or machinery. The survey identifies the right access equipment for each area, such as scissor lifts or mobile elevating work platforms, and the plan allows for aisle widths, floor loading and stock.

6. Removal and disposal of old fittings

Old fittings and lamps are removed and taken away for recycling under the WEEE Regulations. Discharge and fluorescent lamps contain mercury and are handled as hazardous waste.

7. Commissioning and handover

After installation the lighting is tested, sensors are set up and commissioned for each zone, and the system is handed over with documentation. Every Polaris product carries a 5-year warranty, and we offer call-outs, remedial works and planned maintenance afterwards.

What affects cost and timing

We do not publish prices, because every site is different. We price after a survey and lighting design. The main factors are:

• Number and type of fittings, and whether sensors or lighting controls are included.
• Mounting height and access, which decide the access equipment and how fast fittings can be changed.
• Working hours. Night, weekend or phased work fits around operations but can extend the programme.
• Electrical condition. Whether existing circuits, supports and controls can be reused.
• Site rules, such as permits, inductions and areas that can only be worked on at set times.

Payback depends on the wattage saved, the hours of use and your electricity tariff. Our LED high bay upgrade costs and savings guide shows how to work it out, and the LED savings calculator lets you use your own figures. Any figures it gives are estimates.

Compliance and safety

• Electrical installation work is carried out by qualified electricians to BS 7671, the IET Wiring Regulations.
• Lighting levels are designed against BS EN 12464-1, lighting of indoor workplaces.
• Work at height is planned with suitable access equipment and trained operators.
• Where emergency lighting is affected, it is considered in the design, with reference to BS 5266-1.
• Old fittings are disposed of under the WEEE Regulations.

LED high bays we install

• PS-UFO-MAX: UFO high bay with power selectable on site at 100, 150 or 200 W and a plug-in PIR and daylight sensor.
• PS-CURVE: linear high bay with aisle optics for racking.
• PS-MILD: low glare LED high bay.
• PS-ATEX-HIGHBAY: explosion proof high bay for hazardous areas.

For wet or washdown areas we install the IP69K PS-CORROSION LED batten.

See all industrial and warehouse lighting, our warehouse LED lighting page and supply and installation.

Frequently asked questions