The most expensive lighting errors in an industrial new-build project almost always arise because lighting is not considered until very late in the project. Those who install lighting at the end of a project run the risk of making the wrong choice of luminaires, underestimating cabling costs and unnecessary modifications later on. This article answers the most frequently asked questions about lighting planning in industrial new-build projects, from timing and requirements to choosing luminaires and safety.
Which lighting errors cost the most in an industrial new-build project?
The most costly lighting errors in an industrial new-build project are the late engagement of a lighting specialist, choosing fixtures based on purchase price instead of life cycle costs, and ignoring specific environmental requirements. These errors lead to re-installations, premature replacement of fixtures, and sometimes even downtime of production processes.
In practice, we see that lighting is often treated as a finishing touch at the end of the construction phase. By that time, wiring routes are already fixed, mast positions can no longer be adjusted optimally, and the chosen luminaire still does not prove suitable for the actual conditions. That not only costs money, but also time.
The most common and costly mistakes in a row:
- Lighting is only included in the decommissioning phase, which makes wiring and foundations suboptimal.
- Lightings are selected based on the lowest purchase price without taking maintenance and lifespan into account.
- No account is taken of specific environmental factors such as heat, corrosion, dust or vibrations
- The lighting design is skipped, which prevents control of lighting intensity and uniform distribution
- Responsibilities for the lighting plan are not clearly divided between the installer, contractor, and end user.
When should you have an lighting design made for new construction?
An lighting design should be created as early as possible in the design process, preferably simultaneously with the technical base engineering of the building or site. Ideally, you should start with this as soon as the floor plans and the use of the spaces are known. The earlier the design is ready, the more influence you have on wiring routes, masts, and connections.
In practice, this means that a professional lighting advice It must be requested during the design phase, not during or after construction. A well-designed lighting design takes into account the desired levels of illumination per zone, the positioning of fixtures, the wiring routes, and the future maintainability of the installation.
Anyone who delays this until the implementation phase quickly runs into fixed constructions that do not take account of mast positions, penetrations or power groups. This leads to compromises that directly affect the quality of the final installation.
What are the requirements for industrial lighting in harsh environments?
Industrial lighting in harsh environments must withstand the specific stresses of that environment, such as extreme temperatures, humidity, dust, vibrations, corrosion, or the risk of explosion. The exact requirements depend on the application, but the basic criteria are always: sufficient lighting level, mechanical strength, and a protection class that suits the environment.
For environments with high temperatures, such as steel mills or process halls, additional requirements apply to the thermal load-bearing capacity of the luminaires. For outdoor locations at the sea or in the chemical industry, corrosion resistance is crucial. In areas with an explosion hazard, ATEX-certified luminaires are mandatory.
Relevant technical parameters to watch out for:
- IP rating Indicates how well the luminaire is protected against dust and water. For heavy industrial applications, a minimum IP65 rating is common; for higher risk of immersion.
- IK rating: The impact resistance of the luminaire. In environments with heavy equipment or vibrations, a high IK value is essential.
- Temperature range The luminaire must function within the temperatures found in the environment, both high and low.
- Material type: stainless steel, polycarbonate or specially coated aluminum for corrosive environments.
- ATEX certification required in the presence of explosive gases, vapours or dust.
More information about the specific requirements for extreme thermal conditions can be found on the page about High-temperature lighting.
How do you compare LED fixtures for industrial use?
When comparing industrial LED fixtures, you look not only at the wattage or lumen value, but at the overall performance in the specific application. Relevant comparison criteria are light output per watt, the lifespan of the light source, protection class, thermal management, warranty terms, and the availability of spare parts.
A common mistake is to compare luminaires purely on a per-unit price basis. A cheaper luminaire with a shorter lifespan or higher maintenance requirements is ultimately more expensive than a high-quality option. Especially in installations at high altitudes or in hard-to-reach locations, maintenance costs can add up significantly.
When comparing luminaires, also pay attention to the optics of the fixture. For work environments, the light distribution is at least as important as the total light output. A fixture that distributes the light in a focused and uniform manner provides better working conditions in practice than a fixture with high lumen values but poor beam distribution.
Who is responsible for the lighting plan in an industrial project?
In most industrial projects, the responsibility for the lighting plan lies with the client or project manager, but in its implementation it is delegated to an installer or specialized lighting company. In practice, problems arise precisely because no one explicitly assumes this responsibility and lighting falls between the gaps.
For larger projects, it is advisable to include an lighting specialist early in the project team, alongside the constructor, the installer, and the safety coordinator. This way, the lighting plan becomes part of the integrated project planning and not a separate component that has to be added at a later stage.
For the client, it is important to clearly define who will design the lighting, who will approve it, and who will be responsible for delivering the project in accordance with that design. This prevents subsequent discussions about who is responsible if the lighting quality does not meet expectations or operational requirements.
How can you prevent glare and safety issues in industrial work lighting?
You can prevent glare in industrial work lighting by choosing fixtures with a controlled beam and a low UGR (Unified Glare Rating). Additionally, the positioning of fixtures and the mounting height are decisive factors. Misplaced or too bright light sources without shielding cause direct glare or annoying reflections on machines and work surfaces.
In environments where people and machines work together, such as ports, construction sites or production halls, glare is not only annoying but downright dangerous. A machinist who becomes temporarily blinded, or an operator who cannot read the screen due to reflections, constitutes a direct safety risk.
Practical measures to prevent glare:
- Use fixtures with full-cutoff optics that direct the light downward and limit the glare to the side.
- Avoid placing fixtures directly in the field of view of employees or operators
- Opt for an even distribution of illumination to avoid harsh contrasts between light and dark
- Adjust the light color to suit the task: cooler light for concentration work, warmer for storage areas
- Check the UGR values per work zone when designing the lighting design
Practical example: Van Gelder Nijkerk
In Nijkerk, Van Gelder built a new asphalt plant along a canal with bat trails. The lighting had to match the project’s high sustainability ambitions: as low energy consumption as possible and no harm to the bats. JEL The complete environment was calculated in 3D, including the canal and the bat trails, and light design, engineering, installation and retrofitting of the luminaires were carried out. 36 DarkLicht D series luminaires are installed on 15 new light poles measuring 10 and 12 m. With full cut-off light distribution, the installation provides 20 lux on the site, 50 lux in the work areas and an uniformity of 0.55, with less than 0.3 lux on the water.
In a new construction project, mast positions, mast heights and light distribution can still be freely chosen. Subsequent adjustments often mean extra masts, shielding or luminaires that are hung at the wrong height.
A requirement of less than 0.3 lux on the water is moreover only feasible if it is included in the design from the outset. By taking the environment into account before anything is built, diffuse light, glare and ecological prerequisites become part of the plan instead of being a problem upon completion.
Read more about the Van Gelder Nijkerk project
How JEL Products to help prevent lighting errors in industrial new construction
JEL Products It supports industrial clients and project teams from the initial design phase through to commissioning and maintenance. The approach is aimed at preventing exactly the mistakes described in this article: planning too late, incorrect choice of luminaires and unclear responsibilities.
Specifically, JEL Products offers:
- Professional lighting design tailored to the specific environmental requirements of the project
- Advice on choosing luminaires based on life-cycle costs, not just the purchase price
- Specialized LED luminaires for extreme conditions, including high temperatures and corrosive environments, and lighting outside the ATEX zones with referral to a certified Ex manufacturer for the zones themselves
- Guidance during foundation, mast installation and commissioning as part of a total solution
- Support in demonstrating compliance with safety and quality requirements, as an ISO9001 and VCA** certified company
Do you want to prevent lighting from becoming an expensive mistake in your new construction project? Then contact us early so that the lighting plan becomes part of the project planning rather than becoming a problem later on. Please contact JEL Products and discuss the options for your specific situation.