Commercial Lighting Design Using LED Wall Pack and High Bay Lights
Commercial spaces—from warehouses and manufacturing facilities to retail stores and big-box complexes—require lighting designs that balance brightness, efficiency, security, and functionality. A one-size-fits-all approach rarely works: high-ceiling areas need powerful, overhead illumination, while perimeters, entryways, and walkways demand targeted, wall-mounted lighting. The solution? Pairing LED wall pack lights and LED high bay lights—two workhorse fixtures that complement each other to create a comprehensive, cost-effective commercial lighting system.
In this guide, we’ll break down how to design commercial lighting using LED wall pack and high bay lights, covering scene-specific layouts, criteria, strategies, and compliance considerations. Whether you’re redesigning a warehouse, upgrading a retail parking lot, or building a new industrial facility, this article will help you create a lighting system that enhances safety, improves productivity, and slashes energy costs—while optimizing your search presence for queries like “commercial lighting design LED wall pack high bay,” “LED wall pack and high bay combination,” “warehouse lighting design LED,” and “commercial space LED lighting solutions.”
Why LED Wall Packs + High Bay Lights Are the Perfect Commercial Lighting Pair
LED wall packs and high bay lights are designed to address distinct commercial lighting needs—when combined, they create a seamless system that covers every critical area:
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Fixture Type
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Core Strengths
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Ideal Commercial Applications
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LED Wall Packs
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Targeted perimeter lighting, security-focused, weather-resistant, low glare, easy to mount on walls/fences
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Building exteriors, parking lot perimeters, entryways, loading dock edges, walkways, fence lines
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LED High Bay Lights
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Powerful overhead illumination, wide coverage, high lumen output, designed for high ceilings (15–40+ feet)
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Warehouse interiors, manufacturing floors, retail big-box ceilings, gymnasiums, industrial workspaces
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Together, they solve common commercial lighting challenges:
- Eliminate Coverage Gaps: High bays cover open interior/exterior spaces, while wall packs fill in perimeter dark spots.
- Balance Brightness & Focus: High bays deliver broad, overhead light for large areas, while wall packs provide targeted light for security and navigation.
- Maximize Energy Efficiency: Both fixtures use 50–70% less energy than traditional HPS/metal halide, cutting commercial lighting costs significantly.
- Ensure Compliance: Meet local lighting codes (lux requirements, light trespass limits) and safety standards (OSHA, IESNA) with precision.
Step 1: Assess Your Commercial Space & Define Lighting Goals
Before designing, clarify your space’s unique needs and priorities—this will guide fixture selection and layout:
A. Space Type & Key Areas
Identify the core zones of your commercial space and their lighting demands:
- Warehouses/Distribution Centers: Interior storage areas (need high bay lights), loading docks (wall packs + high bays), perimeter fences (wall packs).
- Manufacturing Facilities: Production floors (high bays), assembly stations (targeted high bays + task lighting), exterior perimeters (wall packs).
- Retail Big-Box Stores: Sales floors (high bays + track lighting), parking lots (wall packs + pole-mounted high bays), entryways (wall packs).
- Industrial Complexes: Workshop interiors (high bays), outdoor yards (wall packs + high bays), security checkpoints (wall packs).
B. Lighting Goals & Lux Requirements
Commercial spaces have specific lux (brightness) standards—align your design with these targets:
- General Storage/Warehouses: 100–200 lux (10–20 foot-candles) – enough for inventory picking and navigation.
- Manufacturing/Task Areas: 300–500 lux (30–50 foot-candles) – bright for assembly, quality control, and machinery operation.
- Parking Lots: 50–150 lux (5–15 foot-candles) – balanced for driver visibility and security.
- Entryways/Perimeters: 150–250 lux (15–25 foot-candles) – high for security and visitor safety.
- Loading Docks: 200–300 lux (20–30 foot-candles) – bright for loading/unloading and safety.
C. Constraints to Consider
- Ceiling Height: High bays are designed for 15–40+ feet; avoid using them for ceilings under 12 feet (opt for low bays or wall packs instead).
- Wall Availability: Wall packs require solid mounting surfaces (concrete, brick, steel) – plan placement around existing walls or fence lines.
- Environmental Factors: Outdoor/industrial areas need weather-resistant fixtures (IP65+ for wall packs, IP65+ for high bays in exposed areas).
- Local Codes: Light trespass limits (avoid overlighting neighboring properties), dark sky compliance (shielded fixtures), and energy efficiency standards (IECC).
Step 2: Select the Right LED Wall Packs & High Bay Lights for Your Design
Choose fixtures that match your space’s needs, with complementary specifications:
A. LED High Bay Selection Criteria
High bays are the workhorses of large commercial interiors—prioritize these features:
- Wattage & Lumens: 100–400W (10,000–40,000 lumens) for warehouses/manufacturing; 50–100W (5,000–10,000 lumens) for retail.
- Example: A 20,000 sq. ft. warehouse with 25-foot ceilings needs 200 lux – total lumens = 20,000 × 200 × 10.76 = 43,040,000. Use 20x 200W high bays (21,520 lumens each) for full coverage.
- Beam Angle: 90°–120° for wide coverage (open warehouses); 60°–90° for targeted task areas (assembly lines).
- Color Temperature: 4000K–5000K (neutral/cool white) – enhances visibility and productivity.
- Features: DLC/ENERGY STAR certification, PF ≥ 0.95, dimmable (0–10V), compatibility with motion sensors.
- Mounting: Hook/chain mount (suspended from ceilings) or bracket mount (for high walls).
B. LED Wall Pack Selection Criteria
Wall packs complement high bays by securing perimeters and entryways—focus on these specs:
- Wattage & Lumens: 30–120W (3,000–12,000 lumens) – 30–60W for residential-commercial entryways; 60–120W for industrial perimeters.
- Beam Angle: 120°–150° for wide perimeter coverage; 60°–90° for entryways/signage.
- Color Temperature: 4000K–6000K (cool white) for security; 3000K–4000K for retail/hospitality exteriors.
- Features: IP65+ weather resistance, CRI ≥ 80 (for camera compatibility), dusk-to-dawn photocells, motion sensors.
- Mounting: Wall bracket (fits most commercial wall materials) or fence post mount.
C. Complementary Specs for Seamless Design
Ensure wall packs and high bays work in harmony:
- Color Temperature Consistency: Use the same or similar color temperatures (e.g., 4000K high bays + 4000K wall packs) to avoid jarring light transitions.
- CRI Alignment: Choose CRI ≥ 80 for both fixtures to ensure accurate color rendering (critical for retail, manufacturing, and security).
- Control Compatibility: Select fixtures that work with the same smart system (e.g., DALI, IoT-enabled controls) for unified lighting management.
Step 3: Optimize Layout for LED Wall Packs & High Bays
A well-planned layout ensures uniform coverage, eliminates dark spots, and maximizes efficiency. Follow these scene-specific guidelines:
A. Warehouse/Manufacturing Facility Layout
- Interior High Bay Placement:
- Mount high bays 15–25 feet above the floor, spaced 1.5–2x the mounting height apart. For example, 20-foot mounting height = 30–40 feet between fixtures.
- Align high bays in rows (parallel to aisles) for even coverage of storage areas and workstations.
- Use narrow-beam (60°) high bays over assembly lines and wide-beam (120°) high bays over open storage.
- Exterior/Wall Pack Placement:
- Mount wall packs 12–15 feet high along warehouse perimeter walls and loading dock edges.
- Space wall packs 15–20 feet apart to cover fence lines and outdoor yards.
- Tilt wall packs 15–30° downward to direct light toward the ground (reduces glare for workers and drivers).
- Loading Dock Combination:
- Install 2–3 high bays above the dock (20–25 feet high) for overhead coverage.
- Add 2–4 wall packs on the dock walls (12–14 feet high) to illuminate the loading area and truck beds.
B. Retail Big-Box Store Layout
- Interior High Bay Placement:
- Mount high bays 18–25 feet high, spaced 20–30 feet apart over sales floors.
- Use dimmable high bays (3000K–4000K) to adjust brightness for different sections (e.g., brighter over merchandise, softer over seating areas).
- Parking Lot Combination:
- Install pole-mounted high bays (100–150W) in the center of the parking lot (25–30 feet high, spaced 40–50 feet apart) for broad coverage.
- Add wall packs (60–80W) along the store exterior and parking lot perimeter (12–15 feet high, spaced 20–25 feet apart) to cover entryways and walkways.
- Entryway Focus:
- Pair 2–3 wall packs (40–60W, 4000K) on either side of entry doors for targeted security lighting.
- Use a high bay (100W) above the entry canopy to illuminate the drop-off area.
C. Industrial Complex/Outdoor Yard Layout
- Interior Workshop High Bays:
- Mount high bays 15–20 feet high, spaced 15–25 feet apart over workstations and machinery.
- Use motion-sensor high bays in low-traffic areas (e.g., storage rooms) to save energy.
- Outdoor Yard Combination:
- Install high bays on poles (25–30 feet high, 150–200W) across the yard (spaced 50–60 feet apart) for overhead coverage.
- Line fence lines with wall packs (80–100W, IP66) mounted 12–14 feet high (spaced 15–20 feet apart) to secure perimeters.
- Add wall packs near security gates and checkpoints (100–120W, 5000K) for enhanced visibility and camera performance.
Step 4: Integrate Controls for Efficiency & Functionality
Commercial lighting systems benefit greatly from smart controls—unify wall packs and high bays with these features:
- Dusk-to-Dawn Photocells: Automatically turn on wall packs and outdoor high bays at sunset—eliminates wasted energy.
- Motion Sensors: Pair with high bays in low-traffic areas (e.g., warehouse storage zones) and wall packs in perimeter corners—activates light only when needed (saves 30–50% energy).
- Dimming Systems: 0–10V or DALI dimming for high bays (adjust brightness for task vs. general use) and wall packs (reduce brightness during low-traffic hours).
- Smart Lighting Management: IoT-enabled systems (e.g., Philips Dynalite, Lutron) allow remote monitoring, scheduling, and troubleshooting—ideal for large commercial complexes with multiple zones.
- Emergency Backup: For critical areas (e.g., exit routes, manufacturing floors), choose high bays and wall packs with battery backups—ensures lighting during power outages (complies with NFPA standards).
Step 5: Ensure Compliance & Safety
Commercial lighting designs must meet local codes and safety standards to avoid fines and liability:
- Lux Compliance: Use a lux meter to verify brightness meets target levels (e.g., 200 lux for warehouses, 150 lux for parking lots).
- Light Trespass: Use shielded wall packs and high bays to limit light emission to neighboring properties (most cities cap at 50 lux at property lines).
- Dark Sky Compliance: Choose full-cutoff wall packs and high bays (no upward light) for areas near national parks or residential zones.
- Energy Codes: Ensure fixtures meet IECC standards (efficacy ≥ 100 lumens/W for LEDs) and qualify for DLC/ENERGY STAR rebates.
- Safety Certifications: Select UL/ETL-certified fixtures for electrical safety, and ensure installation by licensed electricians (prevents hazards).
Real-World Case Study: Warehouse Lighting Upgrade (Wall Packs + High Bays)
A 50,000 sq. ft. distribution warehouse in Dallas upgraded from 100x 400W metal halide high bays and 50x 150W HPS wall packs to LED:
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Old System: 100x 400W metal halide (40,000W total) + 50x 150W HPS (7,500W total) = 47,500W. Annual energy cost:
0.15 =12,000/year (bulb/ballast replacements).
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New LED System: 80x 200W LED high bays (16,000W total, 21,520 lumens each) + 50x 60W LED wall packs (3,000W total, 7,200 lumens each) = 19,000W. Annual energy cost: 19,000W × 12 × 365 ÷ 1000 ×
12,402. Maintenance cost: $0/year (50,000-hour lifespan).
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Results: 65% energy savings (
12,000/year), improved visibility (200 lux uniform coverage), and reduced glare. ROI: 2.5 years (after $5,000 rebate).
Common Mistakes to Avoid in Commercial Lighting Design
- Mismatched Brightness: Using low-lumen high bays in manufacturing areas (needs 300+ lux) or overlighting with 120W wall packs in small entryways—wastes energy and causes glare.
- Poor Spacing: Spacing high bays too far apart (creates dark spots) or wall packs too close (causes hot spots)—follow the 1.5–2x mounting height rule.
- Ignoring Environmental Factors: Using non-weather-resistant (IP54) fixtures in outdoor industrial yards—leads to premature failure.
- Inconsistent Color Temperature: Mixing 3000W wall packs with 5000K high bays—creates disjointed lighting and reduces visibility.
- Skipping Controls: Not integrating motion sensors or dimming—misses out on 30–50% energy savings for large commercial spaces.
Final Thoughts: The Power of a Combined LED Lighting System
Designing commercial lighting with LED wall packs and high bay lights creates a holistic solution that covers every critical area—from high-ceiling interiors to secure perimeters. By selecting complementary fixtures, optimizing layout, and integrating smart controls, you’ll enhance safety, boost productivity, and cut costs by 50–70% compared to traditional lighting.
Key takeaways for success:
- Match high bay wattage/lumens to ceiling height and task needs (100–400W for commercial spaces).
- Use wall packs to secure perimeters and entryways (30–120W, IP65+).
- Align color temperature (4000K–5000K) and CRI (≥80) for consistent visibility.
- Follow spacing guidelines (1.5–2x mounting height) to eliminate dark spots.
- Integrate controls (motion sensors, dimming) to maximize energy savings.
If you need help calculating fixture quantities, designing a layout for your specific commercial space, or accessing rebates for LED wall packs and high bays, leave a comment below or contact our lighting experts for a free, personalized consultation!
