Warehouse Lighting Retrofit — Burnaby Industrial
Retrofitted 42 legacy metal-halide high-bays to networked LED across a 24,000 sq ft distribution warehouse — cutting lighting energy use by 68% with zero downtime.
The client's warehouse ran 24/7 shipping operations — any lighting outage would halt fulfillment. Existing 400W metal-halide fixtures were pulling 16,800W continuous and taking 8–12 minutes to restrike after a power blip.
Phased the retrofit into four zones, replacing fixtures overnight during the quieter graveyard shift. Installed 42 x 150W LED high-bays with dimming ballasts and daylight sensors, tied into a DMX-style building controller. Coordinated a $9,400 BC Hydro Business Energy Savings rebate.
Total lighting load reduced from 16.8 kW to 5.4 kW — payback period of 2.3 years. Lux levels at the floor increased by 40%, and the client reported a measurable drop in pick-error rates within the first quarter.
Progress photos.
“The retrofit paid for itself in energy savings faster than we were quoted, and the crew never once shut a shift down. That's rare in this trade.”
