lighting for warehouses and storage

7/24/2019 Lighting for Warehouses and Storage

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The Lighting of Warehousesand Storage Areas

Lighting Guide 006


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Are there any regulations that the lighting

design must comply with?

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).

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 ofthese 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.

Identifying the differing types of

storage facility

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 most common areas may be drawn from the

following either singly or in combination:

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

Rack storage systems at high or low levels

Bin storage with large or small items

Operated using either manual or automatic picking

Packing and despatch areas within thewarehouse interior

Loading bays.

1

*

*

2

3

4

5

6

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.

Introduction

02 Lighting Guide 006


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Comments

May be difficult to maintainat heights above 5m

Usually bare lamp, could cause glare tofork lift truck drivers when accessing

high stacked pallets

400w lamps likely to be toolarge a lumen package for

other than open space areas12

12

8

8

MaximumMinimum

Typical mounting height in metres

5

2.5

5Discharge lamps[any type 150/250w]in Low Bay reflector

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

8

Fluorescent luminairewith Trough reflector

Rack reflector

Lamp and luminaire


Which luminaire?

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 ofany scheme.

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.

Which lamp to use?

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 witha colour-rendering index lower than 80 should not

be used in interiors where people work or stay for

long periods.

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]

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


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Principal light fitting types 05

1 Fluorescent Wide Dispersive ReflectorSpecial application needs

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 impactto 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 forsafety 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 theroof 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.

Principal lightfitting types


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Particularly suited for use in narrow aisledlocations when run parallel with aisle

Tight and precise optical control allowing for

use at higher mounting heights (>5m)

Typical spacing to height ratios 0.75 1.0

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.

Low Bay box type luminaires can be used at 5mmounting heights and above

Available for either 150 or 250w High Pressure

Sodium[HPS] or Metal Halide lamps[MH]

High optical performance with wide transverse

light distributions

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.

3 Discharge High Pressure Sodium [HPS] andMetal Halide[MH]

2 Fluorescent Narrow Distribution withPolished Aluminum Reflector


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Selecting the right illuminance 07

Can be used in a similar way to box types buthaving a circular distribution it is also suitable

for general lighting of open areas. With care,

can be used in a wide aisle location.

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.

4 Low Bay Round Reflector

5 High Bay Reflector for HPS and MH Lamps

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

Availability of a wide range of accessories including

wire guards, glare control louvres and clear visors.

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]

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 aswell as associated loading bays.

Selecting theright illuminance


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Table 3 Illuminance recommendations

Forms of controlLighting controls

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.

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 inputs

The four basic methods of lighting control are:

time based

daylight linked

occupancy linked

localised switching.

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

Store and stockrooms

Dispatch packing handling areas

Automatic high rack storesunmanned gangways

Automatic high rack storesmanned gangways

Automatic high rack storescontrol stations

Loading bays

Maintained Illuminance (Lux) Minimum Colour Rendering (Ra)

100

300

20

150

150

150

60

60

40

60

60

60


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Forms of control 09

Decision chart

Choosing the right controls

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 neededout 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.

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 electricalcontractor 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 daylightpresent.

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.

no

yes

no

no

no

no

yes

yes

yes

no

IS DAYLIGHTAVAILABLE?

CONTINUOUS OR

FREQUENTOCCUPANCY?

REGULAR SHIFTPATTERNS

LIMITED ACCESSROUTE INTO

AREA

LIMITED ACCESSROUTE INTO

AREA

TIME CLOCK

DIRECT SWITCHING

PHOTOCELL LINK

PRESENCEDETECTOR

MAJOR OBSTRUCTIONS& MOVING PLANT


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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 graduallydim 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.

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 unoccupiedor 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.

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.

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.

PIR detector effectiverange up to 12m

Occupancy detectorat end of aisles

Occupancy detectorsat centre of aisles

Long range microwavedetector with effective

range 30 to 50m

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

Occupancy linked

Lighting linked to occupancy, or more appropriately

occupancy patterns, can make considerable savings

in energy usage.


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Application design 11

Application design

How to select the most suitablelighting 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 fewerlamps, 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

Superior lighting design using 3 x 250w HP Discharge lamps

Fittings over-spaced forthe application givinglittle light above floorlevel, heavy shadowscreated and poorvertical illuminance

Fittings spaced so as tolight to the top of thepallet stack, thus givinggood verticalilluminance on allsurfaces with no heavyshadows


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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 excessiveglare 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

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

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.

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.

Bin storage - Manual selection

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.

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 binracks. With conventional dispersive reflectors the

spacing between rows should not exceed 1.5 times

the height above the rack tops.

TraditionalTwin Trough reflector

Rack Rack

12m

RackAisle Aisle

Narrow transversedistribution luminaire


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Application design 13

Floodlighting luminaires for high canopy loading bays

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.

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.

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.

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.

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 aswell as an efficient one.

Peek intensitybelow drivers sight

Floodlight forlighting inside

of a van usedonly when vehicle

is parked

Spacing

Ht

Fluorescent luminairesmounted on trunking.Spacing should notexceed - 1.5 x Ht

Luminaire positioning above racking

Cut-offangle

Cut-offangle


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Can I claim ECAs on myspending 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 aspart 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.


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Contact addresses 15

ContactAddresses

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.

Furtherinformation

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 theBuilding Regulations [ E & W ] explained, CRC 2001

Society of Light and Lighting

Code of Lighting 2002

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 [email protected]

Select

The Walled Garden,

Bush Estate, Midlothian EH26 OSB

Tel 0131 445 5577 Fax 0131 445 5548

E-mail [email protected]


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Action Energy is a Carbon Trust programme. The Carbon Trust is a company limited by guarantee. Registered inEngland and Wales Number 4190230. Registered at: 9th Floor, 3 Clements Inn, London WCA 2AZ.

Whilst we have taken reasonable steps to ensure that the information contained within this Guide is correct, wegive no warranty and make no representation as to its accuracy and we accept no liability for any errors oromissions and nor does the Carbon Trust nor the Government.

Queens Printer and Controller of HMSO December 2002

Ref: ILG006

Tel 0800 58 57 94 www.actionenergy.org.uk

Action Energy is a programme run by the Carbon Trust and funded by

the Department for Environment, Food and Rural Affairs, the Scottish Executive,

Invest Northern Ireland and the National Assembly for Wales.

lighting for warehouses and storage

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