Many warehouses have already switched to LED high bays — and still leave them running at full brightness in empty aisles, all shift, every day.
That is the gap smart lighting controls close. The fixtures decide how much light to deliver, where, and for how long, based on who is actually in the space and how much daylight is already coming in.
This guide follows on from our earlier post on how many lumens your warehouse needs. That post covered how much light to design for. This one covers how to control it once it is installed.
What smart lighting controls actually do
A smart lighting control system is not one device. It is a combination of sensors, dimmers, and a way for the fixtures to talk to each other:
- Sensors detect people, forklifts, and daylight.
- Dimmers lower a fixture instead of just switching it on or off.
- Zones group fixtures by aisle, area, or task, so one aisle can be bright while a closed storage area stays dim.
- A panel or app lets a facility manager change schedules, light levels, and zones without rewiring.
The goal is simple: the right light level, in the right place, only when it is needed.
The five controls that matter most in a warehouse
1. Occupancy sensing
Occupancy sensors switch lights on when someone enters an aisle and dim or switch them off after the space is empty again.
In a warehouse this matters most in aisles that are used in bursts — picking aisles, loading areas, and storage zones that sit empty between tasks. Lights can “follow” workers down an aisle instead of lighting the whole building at full brightness all day.
Ultrasonic sensors detect movement around racking, while infrared sensors detect heat and movement in open areas. Many warehouse sensors combine both. Sensor placement matters as much as the sensor itself: a sensor blocked by tall racking will not see the aisle it is meant to cover.
2. Daylight harvesting
Warehouses with skylights, clerestory windows, or large dock doors already get free daylight for part of the day.
A photosensor measures the daylight reaching the work surface and dims the electric lights to hold a steady light level. On a bright day the fixtures may run at half power or less near the windows, while fixtures deeper in the building stay brighter.
This only works if the sensor is placed where it measures the work surface, not the brightest patch of floor under a skylight, and if the dimming is smooth enough that staff do not notice it changing.
3. Task tuning, also called high-end trim
Many fixtures are brighter than the task actually needs. Task tuning sets a maximum output — for example, capping fixtures at 80% — so they never run harder than necessary.
The difference is often hard to notice by eye, but the power draw drops with the light level. It is one of the simplest controls to set, and it protects the design light level from being exceeded just because a fixture can go brighter.
4. Scheduling and zoning
A schedule turns zones down or off outside operating hours, instead of relying on the last person out to find the switch.
Zoning is what makes the other controls practical. A warehouse is not one room. Picking, packing, shipping, and bulk storage have different hours and different light needs, so they should not all share one switch or one schedule.
Good zoning follows how the building is actually used, not just how the electrical panels happen to be laid out.
5. Wireless control
Wired controls have long been the reliable standard, and they still suit new builds. The 2026 change is that wireless mesh systems — using Bluetooth Mesh or Zigbee — are now commonly used to retrofit older warehouses, because they allow granular, zone-by-zone control without running new control wiring through walls and ceilings.
That makes wireless control a practical option for an existing building where the fixtures are being upgraded but the walls are not being opened. It also makes zones easier to change later if racking moves or a storage area becomes a picking area.
Wireless does not mean weak. In a large metal building, the system still needs a proper layout, with enough fixtures acting as repeaters, so the signal reaches every zone reliably.
Wired or wireless? A simple comparison
| Feature | Wired controls (for example 0–10V or DALI-2) | Wireless controls (for example Bluetooth Mesh or Zigbee) |
|---|---|---|
| Best suited for | New builds and major renovations | Retrofits in existing warehouses |
| Control wiring | Extra low-voltage wiring to each fixture or zone | No new control wiring; fixtures communicate wirelessly |
| Reliability | Very reliable; not affected by wireless interference | Reliable when laid out properly, with enough fixtures in range |
| Changing zones later | Requires wiring changes in most cases | Zones can usually be changed in software |
| Dimming and grouping | Smooth dimming; DALI-2 can address fixtures individually | Smooth dimming; fixtures can be grouped and regrouped in software |
| Cost to install | Higher labour in an existing building | Lower labour in a retrofit; check the cost of the fixtures and gateways |
0–10V is the simplest wired dimming method and suits straightforward warehouse dimming. DALI-2 gives individual fixture addressing and two-way communication, which suits larger facilities that want detailed control and fault reporting. The right choice depends on the size of the building, how often the layout changes, and how much control the facility manager actually wants to use.
Worked example: what task tuning alone can do
This is an illustration, using the same warehouse as our lumens post, with the assumptions stated. It is not a savings guarantee — your result depends on your hours, occupancy, daylight, and fixtures.
- Warehouse: 100 ft × 150 ft, 15,000 sq ft
- Fixtures: 30 LED high bays, 150 W each at full output
- Total load at full output: 30 × 150 W = 4.5 kW
- Operating hours: 12 hours a day, 260 days a year
At full output, all year: 4.5 kW × 12 hours × 260 days = 14,040 kWh a year for lighting.
With task tuning capped at 80%: 3.6 kW × 12 hours × 260 days = 11,232 kWh a year.
That is 2,808 kWh a year less in this illustration, from one setting, before any occupancy sensing or daylight dimming is added.
Occupancy sensing and daylight harvesting add further savings on top of that, but the amount depends on how the warehouse is actually used — how often each aisle is occupied, how much daylight comes in, and how long the building is open. That is why a site assessment, not a catalogue percentage, is the right basis for an estimate.
Mistakes to avoid
- Putting sensors where racking blocks them. A sensor that cannot see the aisle will leave it dark, or leave it lit all day. Walk the aisles and check the sensor’s field of view at rack height, not just at floor level.
- One zone for the whole warehouse. If picking, packing, and bulk storage share a zone, the controls cannot match any of them properly. Zone by use, not by panel.
- Dimming that is too aggressive. Lights dropping to full off in an occupied aisle, or flickering as a sensor hunts for movement, will get the system switched off by staff. Set a safe minimum level for occupied aisles, and a sensible timeout.
- Forgetting emergency and exit lighting. Controls must never switch off emergency lighting. Emergency and exit lighting are designed separately and must stay on their own circuits and controls.
- No plan for who manages the system. A panel or app that nobody is trained to use will stay on its factory settings. Someone on site should know how to change a schedule, add a zone, and check that devices are online.
- Mixing incompatible products. Not every sensor, driver, and gateway works with every other one. Check compatibility before ordering, especially when adding controls to existing fixtures.
- Using uncertified equipment. Fixtures, drivers, and controls installed in Canadian buildings need approved certification, such as CSA or cUL marks, and incentive programs typically cover only products on their approved lists.
What the installation involves
Adding controls to a warehouse lighting system is electrical work, and in a retrofit it is often done in phases so the warehouse keeps operating.
Depending on the system, the work may include:
- Replacing or upgrading high-bay fixtures to dimmable LED fixtures.
- Installing occupancy and daylight sensors at the right height and position.
- Installing a lighting panel, gateways, or keypads, and connecting them to the fixtures.
- Setting zones, schedules, light levels, and timeouts, then testing them in the real aisles.
- Checking that emergency lighting is unaffected and that the system can be managed by the facility team.
Where new regulated electrical circuits or other regulated electrical work are required, the appropriate licensed electrical contractor, permits and Field Safety Representative (FSR) arrangements must be in place.
A good installer also plans around your operations, with phased work and safe access so you don’t lose a shift — and returns to check the settings after the building has been used for a few weeks, when the real occupancy pattern is clear.
A real ATA example: sensors, keypad, and a panel that proves it
In a recent ATA warehouse lighting retrofit, the work was not just new high bays. It included occupancy sensor installation, a lighting keypad, and a lighting panel that showed 65 devices online and 0 offline.
That panel is the difference between a control system and a guess. When the devices are online and reporting, the facility team can see that the sensors, fixtures, and zones are actually working — and can find a fault before it becomes a dark aisle.
What to ask before you choose a system
- Which aisles are occupied, and when? Bring a real operating pattern, not just opening hours.
- How much daylight does the building get, and where?
- Will the layout change in the next few years? If racking moves, wireless zoning is easier to change.
- Who will manage schedules and zones after handover?
- How will you know if a sensor or fixture stops responding?
- What incentive or rebate steps may apply? As a member of the BC Hydro Alliance of Energy Professionals, we can help plan energy-saving lighting upgrades and check what steps may apply — with no rebate amount promised.
Commercial lighting controls by ATA Technical Group
ATA Technical Group is a commercial electrical and general contractor based in Coquitlam, British Columbia, serving warehouses and commercial facilities across the Lower Mainland.
Our services include commercial electrical installations, lighting upgrades and controls, data and network solutions that support connected building systems, and ongoing maintenance and support to keep lighting and controls working as designed.
We can assess your warehouse, review your existing fixtures and panels, and recommend a control approach that fits the building — wired or wireless, phased or complete — with a fast, no-obligation quote.
Planning a lighting upgrade?
Request a free estimate from ATA Technical Group to discuss your warehouse lighting, controls, and energy-saving options. Send us your floor area, ceiling height, operating hours, and current fixtures, and we will take it from there.
Frequently asked questions
Do smart lighting controls work with my existing LED high bays?
Sometimes. It depends on whether the existing fixtures have dimmable drivers and whether they are compatible with the control system you choose. Some fixtures can be upgraded with sensor modules or wireless controllers; others need to be replaced. A site check will tell you which applies.
Will occupancy sensors leave staff in the dark?
They should not, if they are set up correctly. Sensors should be placed to cover the aisle, set to a safe minimum light level while the area is in use, and given a sensible timeout. If lights are switching off while people are working, the sensor position or settings need adjusting, not the idea itself.
Is wireless lighting control reliable in a warehouse?
It can be, when it is laid out properly. In a large metal building, fixtures need to be within range of each other so the mesh network stays connected, and the system should be tested in the real aisles before handover. Wired control remains a strong option for new builds.
How much can lighting controls save?
It depends on the building. The main factors are operating hours, how often each area is occupied, how much daylight is available, and what the existing fixtures use today. That is why we estimate from a site assessment rather than quoting a fixed percentage.
Do I need new wiring for lighting controls?
Not always. Wireless systems can often be added without new control wiring. Wired systems, and any new power circuits, do need proper wiring, permits, and a licensed electrical contractor where required.
Does ATA Technical Group install lighting controls?
Yes. ATA provides commercial electrical, lighting, data network, and maintenance services in the Lower Mainland. Contact our team to discuss your warehouse, existing lighting, and control requirements.
ATA Technical Group
Commercial Electrical & General Contractor
Coquitlam, British Columbia | Serving the Lower Mainland
atatech.ca