Author: Huang Publish Time: 22-01-2026 Origin: Site
Electrical contractors and EPC teams are often asked a simple question with a complex answer: should we keep metal halide high-bays or retrofit to LED? This guide frames that decision for warehouse operations, with total cost of ownership (TCO) as the hero, and practical, low-risk retrofit guidance you can take to the job site. If you’re evaluating a warehouse lighting retrofit and comparing metal halide vs LED high bay options, use the scenario verdicts and TCO math below to make a confident call.
Quick restarts and frequent switching: Choose LED high-bays. They are instant-on with no hot restrike delay, while metal halide (MH) typically needs minutes to warm up and 5–10 minutes to restrike after a power interruption, which risks downtime and safety during outages. Evidence: metal halide operational traits are summarized in the metal halide lamp overview (Wikipedia, 2025-12-16).
Aisles with occupancy/daylight sensors: Choose LED high-bays with 0–10V or DALI-ready drivers. MH systems generally do not dim well and are incompatible with motion-dimming sequences due to warm-up/restrike behavior. Industry documentation emphasizes sensor-readiness for LEDs to capture additional savings beyond fixture efficacy—see manufacturer specs such as Cooper Lighting’s Metalux series for sensor-ready inputs.
High ambient heat or dusty environments: Choose LED models with IP65–IP66 and elevated ambient ratings (often -30°C to +50–65°C). These maintain output and reliability better than MH in harsh conditions.
Budget-constrained phased retrofit: Start with longest-hours zones (e.g., aisles) to capture the largest TCO savings, then plan MH decommissioning and mercury disposal. LEDs deliver efficiency gains immediately; MH maintenance and lamp failures accumulate costs.
Precision task and camera-monitored areas: Choose LED with 80–90+ CRI, anti-glare optics, and low flicker. MH color shifts and glare increase with lamp age, affecting visual comfort and inspection accuracy.
▉The table below summarizes typical 400W MH systems versus modern ~150W LED high-bays for warehouse mounting heights.
| Dimension | 400W Metal Halide High-Bay (system) | ~150W LED High-Bay (2024–2026 generation) |
Typical tech & example | 400W MH lamp + ballast (ANSI M59/M135), probe- or pulse-start | Round/linear LED high-bay luminaire, selectable wattage/CCT options |
System power (W) | ≈455W including ballast losses (often +10–15%) | ≈150W for equivalent delivered light |
Initial lumens & efficacy | 26,000–40,000 lm depending on lamp; 65–115 lm/W family range | 21,000–30,000+ lm typical; 100–150+ lm/W (premium models higher) |
Lumen maintenance | Notable depreciation; maintained output often ~70–80% by ~15,000 h; lamp replacement needed | L70 commonly 50,000–100,000+ h; TM-21 projections frequently >125,000 h at 25°C (e.g., Metalux UHB/UHBS2 TM-21) |
Warm-up & hot restrike | Minutes to full output; 5–10+ minutes hot restrike | Instant-on; no restrike delay |
Controls & dimming | Limited; special ballasts required; poor compatibility with motion/daylight dimming | Widely supports 0–10V/DALI; sensor-ready drivers common (see Metalux SPHB spec) |
Rated life (lamp/driver) | Lamp 15,000–20,000 h (to 50% failures); ballast life varies | LED modules L70 50k–100k+ h; drivers typically 5-year warranty |
Maintenance interval | Relamping cycles (lifts, labor); ballast failures possible | Minimal relamping; occasional driver/component service |
Environmental & compliance | Contains mercury; universal waste disposal rules (see EPA universal waste guidance) | No mercury; DLC listings often enable rebates (see DLC SSL program) |
Operating temp/IP | Fixture-dependent; lamps sensitive to extremes | Ambient -30°C to +50–65°C typical; IP65–IP66 common |
Typical upfront cost (as of 2026-01-22) | Lower lamp cost per piece; fixture/ballast replacement varies | $120–$220 per LED fixture observed in distributor listings |
5–10 year TCO signal | Higher energy and maintenance; downtime risk with restrike | Lower energy and maintenance; additional savings via controls |
Best-for tag | Short hours, limited budgets, legacy holdover only | Most warehouse scenarios; sensor-enabled aisles; high ambient |
Evidence notes and representative sources:
MH characteristics and warm-up/restrike: see Wikipedia’s metal halide lamp (2025-12-16).
LED efficacies and lumen maintenance: manufacturer spec sheets such as Cooper Lighting Metalux series document 100–150+ lm/W and TM-21 projections >100,000 h.
DLC and rebates: DLC SSL program overview explains listing criteria.
Hours of operation: 12 hours/day, 5 days/week, 50 weeks/year ≈ 3,000 h/year.
Electricity rate: $0.10–$0.18/kWh; baseline calculation uses $0.136/kWh, the U.S. commercial average from Oct 2025 reported by the EIA’s monthly update.
Maintenance labor: $80–$120/hr; baseline $100/hr; lift rental priced locally (get quotes).
MH lamp life: 15,000–20,000 h; LED L70: 50,000–100,000+ h (driver service possible).
400W MH system at ≈455W: 0.455 kW × 3,000 h × $0.136 ≈ $185.64/year.
~150W LED: 0.150 kW × 3,000 h × $0.136 ≈ $61.20/year.
Annual energy delta ≈ $124.44 per fixture.
MH ≈ $928 per fixture; LED ≈ $306 per fixture; savings ≈ $622 over 5 years.
MH relamping: At 3,000 h/year, many 400W MH lamps reach relamp around year 5–7; practical warehouses often relamp earlier due to lumen depreciation. Assume one relamp within 5 years and two within 10 years. Labor: 0.5–1.0 hr per fixture (lift + handling). At $100/hr, labor ≈ $50–$100 per relamp; plus lamp cost and lift rental (local quote). Ballast replacement risk adds variance.
LED service: Minimal within 5 years; potential driver swap beyond 7–10 years (labor similar; part cost varies). No lamps to replace.
Illustrative 5-year TCO per fixture (excluding taxes, local fees):
MH: Energy ≈ $928 + Relamp labor/materials (e.g., $150–$250 including lift share) ≈ $1,078–$1,178+.
LED: Energy ≈ $306 + Minimal maintenance (e.g., $0–$50) ≈ $306–$356.
5-year delta: ≈ $722–$872 in favor of LED, before controls savings and rebates.
Occupancy/daylight controls commonly reduce run-time 20–40% in aisles. If LED hours drop from 3,000 to 2,100 h (−30%), annual energy cost ≈ $42.84, improving 5-year savings by another ≈ $91 per fixture versus non-controlled LED—and much more versus MH, which doesn’t dim or cycle well.
If your electricity rate is $0.10/kWh, savings shrink; at $0.18/kWh, savings grow. Long-hours operations (nights/weekends) magnify LED advantages. Always model with local rates, lamp/fixture pricing, and lift costs.
Most warehouses can execute one-for-one LED replacements with hooks or brackets, bypassing MH ballasts and connecting drivers directly to line voltage. Plan wiring for 0–10V (or DALI) if you’ll add controls, confirm mounting hardware compatibility, and review fixture weight and clearances. Where legacy housings are retained, verify ballast bypass kits and space constraints. Finally, schedule safe MH lamp decommissioning under universal waste rules.
Checklist you can take on-site:
Survey mounting heights (18–40 ft), spacing, and photometrics; identify open floor vs aisles.
Verify power, ballast status, and plan for ballast bypass (disconnect safely, label per code).
Confirm mounting hardware (hook/loop/chain/bracket) and fixture weight clearances.
Pull 0–10V control runs for occupancy/daylight sensors; test dimming behavior before handover.
Plan MH lamp/ballast removal, storage, and recycling per universal waste regulations; coordinate with approved handlers.
LED high-bays offer broad CRI options (70–90+) and selectable color temperatures (often 3000K/4000K/5000K). They’re instant-on, flicker-minimized in quality drivers, and can be tuned to the task with optics and anti-glare features—useful for packaging lines and camera systems. Controls are where LEDs unlock extra savings: 0–10V or DALI drivers pair with occupancy/daylight sensors for aisle zones, trimming hours without compromising safety. For rebates, many programs favor luminaires listed under the DLC SSL program; check your utility’s current rules.
In typical warehouse mounting heights, contractors often specify ~150W LED high-bays with 21,000–30,000+ delivered lumens, then tune optics/spacing to the task. Verify photometrics for your racking layout.
Many LED series document L70 at 50,000–100,000+ hours with TM-21 projections exceeding 125,000 hours; a 400W MH lamp family often states 15,000–20,000 hours to 50% failures, with notable lumen depreciation along the way.
Yes. LEDs are instant-on; MH typically needs minutes to warm up and several minutes to hot-restrike. See the general MH operational overview: metal halide lamp.
Can I get rebates for LED high-bays? Often yes—utilities commonly require DLC-listed luminaires. Always check current program criteria.
Are LEDs better for cold storage? Yes. LEDs maintain output in low temperatures and start instantly; MH performance and restrike times can worsen in cold environments.
Disclosure: KEOU Lighting is our product. For contractors planning sensor-ready retrofits in dusty aisle environments, a dimmable LED high-bay option with an IP66 rating can be particularly practical. See KEOU’s dimmable UFO high-bay example on the official site: dimmable LED high-bay. For a broader look at warehouse-ready high-bay options, browse the high-bay category page. Links are provided for reference only; confirm detailed protocols, mounting hardware, and photometric files before specifying.
Next steps for EPCs and contractors: run a quick TCO model with local rates, confirm DLC eligibility, collect lift and labor quotes, pilot one aisle with sensor-ready LEDs, and schedule MH decommissioning and disposal. If you’re mixing legacy MH and LED in a phased plan, prioritize longest-hours zones first to accelerate savings.
