CEE CommLight Warehouse1.0 09242012

Warehouse Lighting
Design Template
for use by electrical contractors

Version 1.0
This design template will be revised, as needed, based on contractor testing relative
to customer satisfaction, ease of use and performance criteria established by the CEE
Comprehensive Lighting Working Group

For more information, contact:
Kate Baldacci
Program Manager
Commercial Lighting Committee
kbaldacci@cee1.org
617-337-9267
Consortium for Energy Efficiency
98 North Washington Street, Suite 101
Boston, MA 02114

September 2012

2 2012 Consortium for Energy Efficiency, Inc. All rights reserved

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Warehouse Lighting Design Template
3
Acknowledgements

While this document represents the work of the entire CEE Commercial Lighting
Committee, we would like to acknowledge Peping Dee of Inform Lightworks, LLC for
his outstanding contributions to this document. This product would also not have
been possible without the resources from the Seattle Lighting Design Lab and the
feedback from efficiency program managers and individuals from lamp, ballast,
control and fixture Original Equipment Manufacturers.

Contents
1 Why Develop a Warehouse Lighting Design Template? ...................... 6
1.1 Building Codes Considered ............................................................................................... 6
1.2 Illuminating Engineering Society Average, Maintained Illuminance
Recommendations ........................................................................................................................... 7
1.3 Illuminance Uniformity Ratios .......................................................................................... 7
1.4 Space Characteristics .......................................................................................................... 8
2 Lighting Fixture Specifications .................................................................. 8
2.1 T5HO Fluorescent High Bay ............................................................................................. 9
2.2 T8 Fluorescent High Bay .................................................................................................... 9
2.3 LED High Bay .......................................................................................................................... 9
2.4 HID High Bay ......................................................................................................................... 10
3 Design Problem and Solution .................................................................. 10
4 Lighting Simulation Results ........................................................................ 11
5 Strategies for Additional Energy Savings .............................................. 12
6 Contractor Checklist ................................................................................... 14
6.1 Visual Task .............................................................................................................................. 14
6.2 Facility Characteristics ...................................................................................................... 14
6.3 Lighting Technologies being considered .................................................................. 14
7 References ..................................................................................................... 16
8 Appendix A Product Renderings ............................................................. 18
8.1 T5HO Fluorescent High Bay ........................................................................................... 18
8.2 T8 Fluorescent High Bay .................................................................................................. 19
8.3 LED High Bay ....................................................................................................................... 20
8.4 HID High Bay .........................................................................................................................22

5
Figures

Figure 1. Maintained Illuminance Recommendations ....................................... 7
Figure 2. Illuminance Uniformity Ratios (average:minimum) ........................ 8
Figure 3. Lighting Simulation Results ................................................................... 11
Figure 4. T5 HO Light Distribution: 1= across, 2 = along ............................... 18
Figure 5. T5HO Fluorescent Pendant High BayError! Bookmark not defined.
Figure 6. T8 High Bay Light Distribution: 1= across, 2 = along ................... 19
Figure 7. T8 Fluorescent Pendant High BayError! Bookmark not defined.
Figure 10. LED High Bay Light Distribution: 1= across, 2 = along ............. 20
Figure 12. LED Pendant High Bay ......................................................................... 21
Figure 13. LED Pendant High Bay DLC Qualified ......................................... 21
Figure 15. HID High Bay Light Distribution: 1= across, 2 = along ........ Error!
Bookmark not defined.
Figure 16. HID Pendant High Bay ......................................................................... 22
Purpose
This Warehouse Lighting Design Template (version 1.0) is being released by
administrators of energy efficiency programs to electrical contractors for pilot
testing and assessment. Program administrators hope to evaluate various aspects of
the use of the template, including such things as: range of savings achieved,
persistence of savings, customer satisfaction and feedback, barriers, and lessons
learned. The goal is to incorporate the results of the testing into later versions of the
template to more completely vet this approach for a successful program lighting
design that cost effectively achieves energy savings.

1 Why Develop a Warehouse Lighting Design
Template?
As lighting components have grown more energy efficient over time, efficiency
program administrators in the United States and Canada, who are charged with
saving energy for public benefit, are looking for ways to continue the positive trend
in saving energy through quality, efficient lighting. One solution that members of CEE
are testing is offering a template to electrical contractors. CEE defines template as a
number of product specifications and recommended layouts for a typical space, in
this case, a warehouse.
Offering a lighting design template for use by electrical contractors that meets
stringent building codes, employs high quality components, and considers typical
space and work requirements may achieve mutually beneficial goals. Efficiency
programs meet their savings targets, and contractors save time and money by
modifying a vetted design for their client.
As a basis for this template, CEE considered:
Energy requirements in national and international building codes
Quality, energy efficient lighting components
Best practices recommended by the Illuminating Engineering Society (IES)
Using a baseline Lighting Power Density(LPD) of either 1.0 (older High Intensity
Discharge (HID) system) or 0.8 (newer fluorescent system) W/sq ft, and
assuming that the replacement fixtures will meet the requirements and best
practices mentioned below, the minimum energy savings potential is 1834
percent over typical existing conditions.
1.1 Building Codes Considered
CEE compared lighting power densities required by national and international
building codes. Specifically, CEE looked at Watts per square foot requirements for
7
warehouse or storage areas for the following codes, all of which are considered
energy efficient.
Code W/sq.ft.
CA Title 24 2008* 0.6
ASHRAE 90.1-2007 0.8
ASHRAE 90.1-2010 0.66
189.1-2009** 0.72
IECC 2012*** 0.6
* CA Title 24 does not allow Whole Building Method for retail
**189.1 requires 10% improvement on 90.1-2007 values
***Draft Value
Source: http://algonline.org/docs/index.php?state-energy-codes

ASHRAE 90.12010 was selected by the committee as the building code to exceed,
since the code is stringent, widely available, and well known.
1.2 Illuminating Engineering Society
Average, Maintained Illuminance Recommendations
All warehouses are going to be different, but contractors can adapt these product
specifications and fixture layouts to achieve the target light levels while saving
energy. The recommendations below are for Warehousing and Storage facilities,
where at least half of observers have visual ages of 2565.
The templates include lighting layout calculations designed to meet horizontal and
vertical illumination recommendations for "Active: Bulky items, large labels
condition".
Figure 1. Maintained Illuminance Recommendations
Source: IES Handbook, 10th Ed. p30.6

1.3 Illuminance Uniformity Ratios
For any given surface, there is a range of illumination. To ensure quality, consistent
light in the space, the ratio should not exceed 5:1.

Horizontal Illuminance Vertical Illuminance
Inactive 50 lux (5 fc) 20 lux (2 fc)
Active: Bulky items, large labels 100 lux (10 fc) 50 lux (5 fc)
Active: Small items, small labels 300 lux (30 fc) 150 lux (15 fc)
Figure 2. Illuminance Uniformity Ratios (average:minimum)
Inactive 5:1
Active: Bulky items, large labels 5:1
Active: Small items, small labels 3:1
Source: IES Handbook, 10th Ed. p30.7, 30.76

1.4 Space Characteristics
The following space characteristics were used to run the light level calculations and
determine the lighting layouts, as they represent a typical warehouse space in CEE
members service territories (based on Seattle Lighting Design Lab and IES
recommendations).
Room Dimensions: 72' length x 150' width x 28' height
Room Surface Reflectances:
Ceiling = 80%
Walls = 30%
Floor = 20%
Fixture Mounting Height = 24' above finished floor
Storage Shelf Dimensions = 3.4' depth x 10' width x 16.3' height
Storage Shelf Reflectances:
Horizontal Structure = 80%
Vertical Structure = 30%
Shelf = 50%
Aisle Width = 11.2'
It is important to note that results may vary depending on actual project conditions;
modify the various factors taken into consideration in our calculations to match your
actual project conditions and requirements. If your project requires greater fixture
mounting height and fixture on-center spacing, or the average operating ambient
temperature is higher than 25C, it is highly recommended that a new simulation or a
full-scale mock-up is performed to evaluate how these actual project conditions
affect the lighting in your space.

2 Lighting Fixture Specifications
Installed correctly, these fixtures have the potential to meet the goals above given
their efficiency, lighting capacity and quality characteristics. Selecting fixtures that
meet the performance criteria listed below will help to ensure that quality, energy
efficient products are used in this upgrade.
9
2.1 T5HO Fluorescent High Bay
Fixture Description: Pendant-mounted direct fixture with louver
Fixture Dimensions: 9.75"W x 4.25"H x 46.125"L
Number of Lamps in cross-section: 2
Type of Lamp: F54T5HO
Initial Lumen Output per Lamp @ 25C: 4,500
1
Lamp Life: 30,000 hrs. @ 3hr/start; 36,000 @ 12hr/start

Lamp Lumen Depreciation: 0.92
Ballast: Electronic Programmed Start
Ballast Factor: 1.0
System Wattage @ 120V: 119W
Fixture Efficiency: 98.8%
2.2 T8 Fluorescent High Bay
2
Fixture Description: Pendant-mounted direct fixture (louver/14% uplight)

Fixture Dimensions (WxHxL): 9.75" x 4.69" x 48"
Type of Lamp: F32T8
Initial Lumen Output per Lamp: 3100
Lamp Life: 36,000 hrs. @ 3hr/start; 42,000 @ 12hr/start
Fixture Efficiency: 89%
2.3 LED High Bay
3
Fixture Description: Pendant-mounted direct fixture with lens

Number of Lamps in cross-section: N/A
Type of Lamp: LED
Delivered Lumens: 10,200
Lamp Life L70: 60,000+ hrs.
System Wattage: 145W

1
There is a significant drop in lumen output between the 3000K/3500K/4100K and 5000K/6500K
groups. In this document, lumen output shown and used in the calculation reflect values for the
3000K/3500K/4100K lamp group for both T8 and T5HO. If 5000K and 6500K lamps are used, more
lamps and fixtures may be needed to hit target illuminance and uniformity levels.
2
A list of lamps and ballasts that meet the T8 requirements can be found by viewing the High
Performance T8 qualified product lists on the CEE Website.

3
A list of fixtures that are qualified to meet these requirements can be found at the Design Lights
Consortium website by sorting for high bay fixtures 80lpw. Note that not all fixtures listed meet this
performance level.
Luminaire Efficacy: 80 lumens per watt
2.4 HID High Bay
Fixture Description: Pendant-mounted direct fixture
Fixture Dimensions (DxH): 16" x 23"
Type of Lamp: Ceramic Metal Halide
Initial Lumen Output: 24,000
Lamp Life: 20,000 hrs.
Ballast: Electronic Low Frequency SQ Wave Pulse Start
Ballast Factor: 1.0

Please see Appendix A for detailed renderings and characteristics.

3 Design Problem and Solution
Typical Design Problem Most of the visual tasks in rack storage and aisles in
warehouse facilities occur in the vertical plane (e.g., moving materials on and off
storage shelves), so uniform vertical illuminance is more critical than horizontal
illuminance. Identifying the right solution requires careful consideration of many
factors to ensure that the lighting design is energy efficient and provides a quality
visual environment that is supportive of the visual tasks and well being of the
building occupants.
Solution Mount over the center of each aisle efficient linear fluorescent, LED, or metal
halide high bay fixtures with optical systems designed to deliver vertical illuminance
on the front of each storage rack. Discomfort glare must be minimized by using
louvers, lenses or diffusers to shield the light source from direct view. Lamps with
color rendering index of 85 or greater must be selected whenever visual tasks
include color matching or color discrimination. Flicker and strobe effects must be
managed to ensure safety.

11
4 Lighting Simulation Results
This is a summary of calculation results for each lighting system, based on assumed
warehouse space characteristics as described in Section 1, and on photometric files
of the fixtures described in Section 2.
4
Weve also included the number of fixtures used, and the fixture mounting height
above finished floor and its spacing in our simulated space. It is important to note
that the number of fixtures used, fixture mounting height, fixture on-center spacing,
operating ambient temperature, lighting system performance characteristics, or
space characteristics that significantly differ from the one shown in this template
may yield significantly different results. If your project requires greater fixture
mounting height and fixture on-center spacing, or the average operating ambient
temperature is higher than 25C, it is highly recommended that a new simulation or a
full-scale mock-up is performed to evaluate how these actual project conditions
affect the lighting in your space. Please contact your lighting designer or engineer,
your lighting sales representatives, fixture manufacture, or sales department for
assistance.

Figure 3. Lighting Simulation Results
T5HO High Bay T8 High Bay LED High
Bay
HID High Bay
Mounting height 24' AFF 24' AFF 24' AFF 24' AFF
On-center spacing 18'x12' 18'x12' 18'x20' 18'x30'
Number of fixtures 48 48 28 20
Horizontal
illuminance (fc)
18.7 14.1 15.4 12.4
Vertical illuminance
(fc)
9.8 7.7 6.4 7.3
Vertical uniformity
(avg:min)
1.93 2.02 2.79 2.35
Lighting power
density (W/ft
2
)
0.53 0.38 0.38 0.49
Please see Appendix A for rendered views for each of the simulations.

4
All initial lumen output used in the calculations assume installed ambient temperature of 25C. An
increase of 10C in installed ambient temperature can result in 2% to 10% in lumen output, depending on
the lighting technology used.
5 Strategies for Additional Energy Savings
These strategies are not included in the expected savings ranges indicated in Section
1, though when designed, installed, commissioned and maintained properly may
significantly reduce power consumption and operating costs of warehouse facilities.
PIR Occupancy Sensor An occupancy sensor is a single- or bilevel switching device
that turns lights on, either automatically or manually, or off, depending on whether it
"sees" motion in a room or a particular area within a large space [5]. Typical energy
savings is anywhere from 3545% [7]. PIR sensors do not "see" around corners,
making them perfectly suited for warehouse rack aisle application.
Ultrasonic Occupancy Sensors These emit ultrasonic waves throughout the space and
"see" motion when it detects a change in the return frequency of the reflected
ultrasonic waves, as compared to the "acoustic signature" for a vacant space [10].
Unlike PIR sensors, ultrasonic occupancy sensors can "see" around corners and can
detect movement even when there are obstructions between the sensor and the
occupant. Ultrasonic sensors are recommended for applications where there is not a
direct line of sight between the sensor and the occupant, such as winding corridors
or stairwells. Bilevel dimming systems that dim the lights down to a predetermined
lower power level when corridors and stairwells are not occupied have been shown
to have energy savings potential of 4050% [11].
Daylight Harvesting Photosensors When photosensor readings indicate there is
adequate light from skylights, the electric lighting must respond by dimming
(photosensor dimming) or switching off luminaires (photosensor switching) to
reduce energy consumption. The daylight harvesting control system should include a
five-minute time delay to minimize cycling due to rapidly changing sky conditions. A
one-minute fade rate to change the light level is also preferred [6]. Open-loop
photosensors are recommended for warehouse spaces [6]. Daylight harvesting
controls offer the added benefit of reducing peak demands by dimming or shutting
off lighting systems during peak demand hours, a period when daylight is generally
plentiful [14]. A field study conducted by the Lighting Research Center on their
Integrated Skylight Luminaire measured energy savings with and without
photosensor controls, and found that including photosensor controls increased
energy savings by an additional 28% [15].
Load Shedding Dimming noncritical lighting during periods of peak electric demand
is a sound demand response (DR) strategyone that can be repeatable, predictable
and immediate [16]. Dimmable lighting systems capable of demand response (DR)
typically consist of three parts: addressable luminaires (or light fixtures), a signaling
device to send the dimming command to the luminaire (or light fixture), and a
communication system to receive the DR signal and control the signaling device.
13
There are many lighting control technologies that can accomplish this. The system
demonstrated in the referenced study is limited to T8 linear fluorescent
lamps/fixtures, but other systems have the ability to control many load types for DR.
In the study, the load-shedding ballasts are essentially NEMA Premium instant-start
ballasts with bilevel dimming and integral power line carrier signal receiver for
automated dimming response [16], but any continuous dimming ballast (or
driver/power source) with compatible lamp type can be used. Specific to the system
in the study, the signaling device is installed at the electrical distribution panel. Many
of these systems can be operated manually, tied to a building management system,
or can be controlled over the Internet. In the Delta study, the 33% fixed power
reduction built into the load-shedding ballasts yielded an average demand reduction
of 32% across the five field demonstration sites [16]. Generally, a continuous dimming
system is preferred because the dimming level can be tuned for specific lighting
levels and demand reductions.
When demand response is used to curtail energy usage at participating facilities,
specific reduction of electrical loads during a peak demand event is required by
contract. One opportunity for demand response or peak shaving is to incorporate a
lighting control system with the capability to dim and reduce demand during a
demand response event.
Integrated Skylight Luminaire The Lighting Research Center at Rensselaer Polytechnic
Institute developed a lighting system, where each unit combines a skylight, a sunlight
diffuser box, (4) 3-lamp T8-based electric luminaire assemblies and a photosensor
with an electronic controller. The photosensor is installed within the well of the
skylight and is connected by a low voltage cable to the luminaire controller. The T8
fixtures are stepped-dimmed, continuously dimmed, or turned off, depending on the
amount of available daylight. Compared to the existing 400W Metal Halide fixtures,
the Integrated Skylight Luminaires with photosensor controls were found to reduce
energy consumption by 40% [15].
Advanced Energy Management and Reporting Software Integrating an advanced
energy management and reporting software into a lighting control system provides
computerized control of a facilitys lighting from a central software application and
reports on a buildings energy performance. In addition, personal control of lighting
can be given to employees from their desktop PCs. Reports on lighting energy
consumption, cost savings, occupancy data and building lighting usage can be
generated to analyze a specific area or location within your building. This type of
software maximizes energy management strategies (i.e., daylight harvesting,
occupancy sensing, load shedding, etc.) by identifying operational inefficiencies and
productivity levels within a facility. A facility or sustainability manager could then
easily make adjustments to improve the overall savings in lighting energy usage and
consumption and reduce the facilitys carbon footprint. This energy reporting is a
useful tool to show building management/executives, utilities, or ESCOs in the case
of a performance contract, that specified energy goals have been met.

6 Contractor Checklist
The intent of this section is to give specifiers a list of considerations and questions,
designed to ensure that suitable lighting productsonly those that meet minimum
performance criteriaare specified on warehouse projects.
The list of questions below is intended to take lighting professionals through a series
of closely related design considerations. Answers to the initial questions determine
how subsequent questions must be answered.
6.1 Visual Task
What items are being stored in the facility?
Are packaging labels in large or small print? Are they read visually or
electronically?
Is color matching or color discrimination an important part of building occupants'
tasks?
How often are lights left on?
Are the lights required to be on at their full light levels when the space is
unoccupied?
6.2 Facility Characteristics
What is the total square footage of the warehouse facility?
What is the ceiling height?
What is the aisle spacing?
Are the spaces conditioned? What is the typical or seasonal temperature range
that might affect the selection of appropriate lighting technology?
What types of rooms are in the warehouse facility (i.e. cafeteria, offices, parking
garage)?
Are the room surfaces bright or dark (ceiling, walls, floor)?
What energy management strategies can be applied to the facility?
6.3 Lighting Technologies being considered
What lamp technology is primarily being considered?
What is the system efficiency or efficacy (LED- lumens per watt)?
Is the lumen output of the lamp or fixture selected adequate given the room
ceiling height?
What is the light distribution coming out of the fixture? Does it resemble the
shape of the light distribution presented in the CEE templates? Is it appropriate
for rack aisle application?
Will occupancy sensors be installed? If so, ballast type selected must be checked
for compatibility with other components of the lighting system.
15

7 References

[1] Murray, Robert. 2012 Dodge Construction Outlook, McGraw Hill Construction, New
York, NY, October 2011.
[2]
http://www.eia.gov/emeu/cbecs/cbecs2003/detailed_tables_2003/2003set1/2003
pdf/a1.pdf
[3] IESNA Lighting Handbook. 10 Edition. David DiLaura, Kevin W. Houser, Richard G.
Mistrik, Gary R. Steffy editors.
[4] IESNA. 2001. IESNA RP-7-01, Lighting Industrial Facilities. New York: Illuminating
Engineering Society of North America.
[5] http://algonline.org/docs/index.php?occupancy-vacancy-sensors
[6] Advanced Energy Design Guide for Small Warehouses and Self-Storage Buildings
(30% Energy Savings), June 2008.
[7] http://www.lightingdesignlab.com/articles/occ_sensor/intro_occsens.htm
[8] "Adaptive Corridors: University of California, Davis." California Energy
Commission's Public Interest Energy Research Program.
[9] http://lightingcontrolsassociation.org/lca/projects/industrial
[10] http://algonline.org/docs/index.php?occupancy-sensing-technologies
[11] http://cltc.ucdavis.edu/content/view/891/436/
[12] http://algonline.org/docs/index.php?occupancy-sensing-technologies-4
[13] http://clt.ucdavis.edu/content/view/891/436/
[14] http://clt.ucdavis.edu/content/view/891/436/
[15] Lighting Research Center (LRC). "Integrated Skylight Luminaire". Field Test
Delta, January 2003.
[16] Lighting Research Center (LRC). "Demand-Response, Load-Shedding Ballast
System". Field Test Delta, October 2011.
[17] Table BC-11, US Department of Energy, Energy Information Administration, 1998.
A Look at Commercial Buildings in 1995: Characteristics, Energy Consumption and
Energy Expenditures, DOE/EIA-0625(95), Washington, DC
17
[18] Skylights as luminaires: PIER skylight photometric test results, IESNA Annual
Conference, August 2002
[19] R. Leslie. "Successful Daylighting Techniques and Technologies, Better Buildings
By Design 2008 Conference
[20] Next Generation Lighting Industry Alliance with the U.S. Department of Energy,
Second Ed., June 2011. LED Luminaire Lifetime: Recommendations for Testing and
Reporting.
[21] http://lightingcontrolsassociation.org/wireless-lighting-controls-offer-flexibility-
and-cost-savings-in-commercial-buildings/
[22] http://www.nema.org/stds/le6.cfm Target Efficacy Rating for Commercial,
Industrial and Residential Luminaires
[23] http://www.nema.org/stds/le5.cfm Luminaire Efficacy Rating for Fluorescent
Luminaires
8 Appendix A Product Renderings
8.1 T5HO Fluorescent High Bay
Fixture Description: Pendant-mounted direct
fixture with louver
Fixture Dimensions: 9.75"W x 4.25"H x 46.125"L
Type of Lamp: F54T5HO
Initial Lumen Output per Lamp @ 25C: 4,500
5
Lamp Life: 30,000 hrs. @ 3hr/start; 36,000 @
12hr/start

Ballast Factor: 1.0

Figure 4. T5 HO Light Distribution: 1=
across, 2 = along

Figure 5. T5HO Fluorescent Pendant High Bay

5
There is a significant drop in lumen output between the 3000K/3500K/4100K and 5000K/6500K
groups. In this document, lumen output shown and used in the calculation reflect values for the
3000K/3500K/4100K lamp group for both T8 and T5HO. If 5000K and 6500K lamps are used, more
lamps and fixtures may be needed to hit target illuminance and uniformity levels.
19
8.2 T8 Fluorescent High Bay
6
fixture (louver/14% uplight)

Fixture Dimensions (WxHxL): 9.75" x 4.69" x 48"
Type of Lamp: F32T8
Initial Lumen Output per Lamp: 3100
Lamp Life: 36,000 hrs. @ 3hr/start; 42,000 @
12hr/start
Fixture Efficiency: 89%

Figure 6. T8 High Bay Light Distribution:
1= across, 2 = along

Figure 7. T8 Fluorescent Pendant High Bay

6

6
A list of lamps and ballasts that meet the T8 requirements can be found by viewing the High
Performance T8 qualified product lists on the CEE Website.
8.3 LED High Bay
7
fixture with lens

Number of Lamps in cross-section: N/A
Type of Lamp: LED
Delivered Lumens: 10,200
Lamp Life L70: 60,000+ hrs.
Luminaire Efficacy: 80 lumens per watt

Figure 8. LED High Bay Light
Distribution: 1= across, 2 = along

7
A list of fixtures that are qualified to meet these requirements can be found at the Design Lights
Consortium website by sorting for high bay fixtures 80lpw. Note that not all fixtures listed meet this
performance level.
21
Figure 9. LED Pendant High Bay

Figure 10. LED Pendant High BayDLC Qualified


8.4 HID High Bay
Fixture Description: Pendant-mounted direct fixture
Fixture Dimensions (DxH): 16" x 23"
Type of Lamp: Ceramic Metal Halide
Initial Lumen Output: 24,000
Lamp Life: 20,000 hrs.
Ballast: Electronic Low Frequency SQ Wave Pulse
Start
Ballast Factor: 1.0
Figure 11. HID High Bay Light
Distribution: 1= across, 2 = along
Figure 12. HID Pendant High Bay

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