It might not be something we think about often or pay much heed to, but lighting has a major role in workplaces. Workplace lighting safety has a direct impact on the safety of workers, their level of output, and the quality of work they produce.
How lighting affects workplace safety
In any workplace, specifically industrial settings, poor lighting can have serious consequences. The purpose of lights in these areas is not just to increase illumination, but to reduce the risk of accidents. Inadequate lighting can lead to trips, falls or critical errors when operating large machineries, hazardous materials or critical infrastructure. Areas such as stairwells, loading docks and narrow passageways are especially vulnerable when lighting is poor.
Adequate lighting also helps identify potential hazards, spillage and obstacles, reducing the risk of injuries and accidents. Additionally, having well-lit emergency exit routes
Benefits of industrial LED lighting
High quality industrial LED lighting and workplace lighting safety has some key benefits, including:
- Improved visibility of tasks, equipment, obstacles and hazards, preventing accidents and allowing workers to operate safely and efficiently.
- Good quality light also reduces eye strain and headaches by reducing glare, flicker and shadows. This helps reduce fatigue and discomfort.
- Better lighting also means better task productivity as workers are more alert.
- A dimly-lit environment is very sad and demotivating to work in, however, with better lit areas, the morale of workers remain high and they work more effectively.
- Using industrial LED lights is also energy-efficient and helps in saving money for your entire operations.
Key features to consider before lighting design for industrial safety
Here are some key considerations when evaluating and selecting lighting design for industrial safety:
- Light levels should be adequate as per industry standards such as 250 lux for warehouses and 1000+ lux for detailed tasks.
- Light should be uniformity and consistent without areas of dark and bright areas. Better uniformity enhances visibility and safety.
- Flicker-free lighting using LED technology also helps improve safety.
- Optimal colour helps render accurate visibility and differentiation of objects. For example, white light helps with focus.
- Automatic lights that can easily be controlled to change settings based on occupancy and daylight.
- Task specific lighting so that the purpose of each area is met, rather than uniform bright lights.
Best lighting for manufacturing plants
Different areas in the industrial setup require different levels of illumination. Let us look at some of the best light for different areas in a manufacturing plant:
Large Areas
Areas that are huge in size like loading docks, storage spaces, warehouses or assembly lines need to have high bay LED light.
- They should have upto 50,000 lumens for vast coverage.
- Be equipped with motion/occupancy sensor to maximize efficiency.
- Low-profile and lightweight design to enhance look and functionality.
- Be raised to a higher level for more ground coverage.
Precision Work
Many areas in the plant will be dedicated to particular task like machinery, assembly benches, inspection stations and others. These areas need task lightings for efficient industrial lighting that help them get more visibility and work productively.
- Adjustable lamps or lights that have flexibility to aim directly at the task.
- LED strip lighting to illuminate work areas.
- Arm lamps that can be easily manipulated.
- Low-glare lights to reduce accidents.
- Localised quality illumination also helps with less strain and errors.
- Accident prevention lighting for these task areas is also important.
- Lighting to improve productivity must be direct, antiglare, soft and perfectly illuminating.
Emergency Areas
It is imperative that any industrial place has emergency light settings that can be used during power outages to help with evacuation and also prevent mishaps.
- Centralised power generator with backups that supports lighting in all critical areas.
- Self-contained emergency LED lights with integrated batteries.
- LED exit signals that work even in case there is a fire and dense smoke.
- Remote control and alert system to monitor system status.
Where to use motion sensors in industries?
Motion sensors that automatically switch on and off based on movements help with energy saving. They can be used in:
- Aisle ways and corners
- Building perimeter
- Outdoor wall lighting
- Stairways and hallways
- Loading docks
OSHA lighting requirements
Occupational Safety and Health Administration (OSHA) has recommended lighting regulations for workplace that vary based on the type of work carried out in the place and commercial requirements.
For offices, it recommends a well- distributed rows of diffuse lights parallel to the line of sight along with supplemental task and desk lighting. The use of blinds on windows to eliminate bright lights is also essential. As offices require a calming touch, it is recommended to use light colours and matte finish on walls and ceiling to soften light reflections and reduce contrast.
The typical lux level or the measurement of light falling on a surface required on common commercial installations are:
- Offices, laboratories, and show rooms: 500 lux
- Factories and workshops: 750 lux
- Warehouse loading bays: 300–400 lux
- Lobbies, corridors, and stairwells: 200 lux
- Warehouse aisles: 100–200 lux
Other than this, OSHA also mentions that light fixtures must be placed at least 7 feet above work surfaces, have shatterproof shield, no exposed live parts and be firmly mounted to the wall.
It also covers application gaps such as uncovered light fixtures, exposed lighting parts and poor illumination as some of the major missteps by industries leading to violation of industrial lighting standards.
Lighting systems for hazardous areas
Lighting systems that work well in harsh conditions are the basic necessity for any industrial plant. These light systems are specifically designed to withstand harsh conditions without incident. Hazardous area lighting refers to lighting fixtures that are certified to be used in areas where there is a risk of fire, explosion, presence of flammable gases, liquid, combustible dust or any other harmful material.
Lighting systems for hazardous areas are constructed with sturdy and durable materials along with sealed enclosures, explosion-proof housing and specialised lenses that help prevent any aggravation.
Smart lighting for industrial spaces
Modern-day lights are increasingly becoming smarter and its application in industrial settings can be highly beneficial from the standpoint of safety as well as economics.
Smart LED lights have lower maintenance cost and provide good return on investments. The energy saving of these lights allow the company to be more mindful about their sustainability commitment as well as their bills.
Smart factory lighting safety allow for remote monitoring, reporting and creating alerts whenever needed based on their real-time assessment. With enhanced safety and comfortable light levels that can be adjusted from anywhere, smart lighting for industrial spaces is the future for industries.
Regular audits for efficient industrial lighting
As lighting technology keeps changing, it is important to periodically review and asses lightings to leverage latest advancements. Best practices include:
- Conduct lighting audits every 2-3 years.
- Review industry standards and ensure your lighting for industrial facilities match them.
- Evaluate light efficiency and replacing lights that are consuming a lot of power.
- Upgrade old systems with smart lighting technology.
- Review energy bills and address any issues.
- Checking of light levels, uniformity and colour quality are maintained.
Ensuring factory lighting safety and correct warehouse lighting systems can help with good returns in terms of better productivity and low accident rates.
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