Installing LED high bay lights can dramatically improve illumination in warehouses, factories, gymnasiums, and other large indoor spaces. However, even the most advanced lighting fixtures can underperform—or fail entirely—if installed incorrectly.
To help you get the best performance and longevity from your investment, we’ve compiled the most common mistakes people make when installing LED high bay lights and how to avoid them.
Using the Wrong Mounting Method
Why it’s a problem:
LED high bay lights are designed for specific mounting options such as hook mounts, chain mounts, or brackets. Using the wrong method can cause uneven illumination, instability, or even safety hazards.
How to avoid it:
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Check the manufacturer’s installation instructions before choosing a mounting style.
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Match the mounting type to your building’s structure and the fixture’s weight.
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Ensure all mounting hardware is rated for the load.
Example:
A hook mount is quick and easy for open-ceiling warehouses, while bracket mounts are better for spaces with flat ceilings or angled beams.
Incorrect Height and Spacing
Why it’s a problem:
If fixtures are mounted too high, the light output may not reach the working area effectively. If mounted too low or spaced too far apart, you may get dark spots or glare.
How to avoid it:
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Use the mounting height and spacing chart provided by your supplier.
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As a general guideline:
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12–20 ft ceiling height: 10–12 ft spacing
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20–30 ft ceiling height: 15–18 ft spacing
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30–40 ft ceiling height: 20–25 ft spacing
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Consider beam angle when determining spacing.
Poor Wiring and Electrical Connections
Why it’s a problem:
Loose connections, incorrect wire gauge, or lack of grounding can cause flickering, overheating, or electrical hazards.
How to avoid it:
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Always turn off power before installation.
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Follow the National Electrical Code (NEC) or your local electrical standards.
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Use the correct wire size for your fixture’s wattage and voltage.
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Double-check all connections before restoring power.
Ignoring Environmental Conditions
Why it’s a problem:
Not all LED high bay lights are suitable for every environment. Installing a non-waterproof fixture in a high-humidity or dusty location will shorten its lifespan.
How to avoid it:
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Check the IP rating of the fixture.
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IP65 or higher for wet/dusty areas.
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IP20–IP40 for clean, dry indoor spaces.
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Consider operating temperature limits if the fixture is installed in freezers, furnaces, or outdoor settings.
Skipping Post-Installation Testing
Why it’s a problem:
Even if everything looks right, small issues like loose screws, incorrect angles, or unbalanced lighting can go unnoticed without testing.
How to avoid it:
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After installation, turn on all lights and inspect the area for dark spots or glare.
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Use a lux meter to measure illumination levels and compare them to your lighting plan.
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Make adjustments before the workspace is in full use.
Not Considering Future Maintenance
Why it’s a problem:
If fixtures are installed without easy access, replacing or cleaning them later will be difficult and costly.
How to avoid it:
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Choose mounting points with safe ladder or lift access.
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Plan cable routes so they are easy to reach without dismantling other equipment.
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Keep a record of fixture locations, models, and installation dates.
Final Thoughts
Proper installation is the foundation for getting the most out of your LED high bay lighting system. By avoiding these common mistakes—wrong mounting methods, poor spacing, bad wiring, ignoring environment factors, skipping testing, and overlooking maintenance—you can ensure your lighting is safe, efficient, and long-lasting.
If you’re unsure about any step, work with a licensed electrician or lighting professional to guarantee a flawless installation.
