Converting Fluorescent Tube Light to LED - Upgrade Your Shop Lights

If you’re still using fluorescent fixtures in your facility or workshop, you’re not alone-fluorescents have been a common standard for decades. But rising energy costs, frequent ballast/tube issues, and disposal requirements are all reasons many shop owners and contractors now consider upgrading to LED lights for shops.

In many applications, LED upgrades can reduce lighting energy use significantly while improving light quality and lowering routine maintenance (fewer tube and ballast-related service calls). Actual results vary by fixture type, operating hours, and layout.

With LED lighting, many facilities see meaningful energy savings-often 40–60%-especially when replacing older fluorescent systems and optimizing controls. In addition, LEDs do not contain mercury (unlike most fluorescent lamps), which can simplify handling and end-of-life management.

Important: Electrical work should be performed by a licensed electrician and must comply with local codes. Disposal rules vary by state and municipality. Fluorescent lamps often require specific recycling/handling due to mercury content; LEDs may also be subject to electronics recycling requirements in some areas. Always follow local disposal and recycling regulations.

While LEDs can have a higher upfront cost than legacy technologies, pricing has improved substantially in recent years. Because energy and maintenance savings begin immediately after installation, many projects achieve practical payback timelines – depending on operating hours and utility rates.

Options to Convert Your Shop to LED

When converting fluorescent lighting to LED, there are two common approaches: retrofit (reuse the existing housing) or replace (remove the fixture and install a new LED fixture). Both approaches can be effective-your best option depends on the condition of your current fixtures, desired performance, and budget.

Regardless of the method, work with a licensed electrician so the installation is safe and ready for inspections and future service.

Option 1: Retrofit Fluorescent Fixtures to LED

If your existing housings are in good shape (structurally sound, not corroded, and appropriate for the environment), an LED tube retrofit can be a cost-effective path. Retrofitting may involve ballast removal and rewiring, so professional installation is strongly recommended.

LED tubes are designed to resemble fluorescent tubes and fit in similar fixture formats. In most cases, there are two main types of LED tubes:

• Ballast-compatible (plug-and-play): Designed to operate with certain existing ballasts. Compatibility is not universal, and if the ballast fails later, the lamp will not operate until the ballast is replaced.
• Direct-wire (ballast-bypass): The ballast is removed/bypassed, and AC power is wired directly to the lamp holder. Many direct-wire tubes are single-ended, which typically requires non-shunted lamp holders and correct wiring to manufacturer’s instructions.

Tip: Retrofit success depends on workmanship and maintaining proper wiring and lampholder compatibility. Always follow the LED tube manufacturer’s wiring diagram and safety instructions.

Option 2: Replace Old Fluorescent Fixtures with New LED Fixtures

If your fluorescent fixtures are damaged, corroded, poorly distributed, or simply not delivering the results you need, complete fixture replacement is often the best long-term solution. While replacement is typically more expensive than retrofitting, it can provide improved optics, better distribution, and fewer legacy components.

Common LED replacements for shop and light industrial spaces include linear fixtures, vapor-tight fixtures (for dusty or damp areas), round UFO-style high bays, and low-bay fixtures.

Switching from Fluorescent Shop Lights to LED Fixtures

Compared to fluorescents, LEDs can deliver brighter, more uniform lighting with fewer common fluorescent issues (buzzing ballasts, end-of-life flicker, and frequent tube changes). Many LED fixtures also use sealed housings and durable lens materials that can reduce maintenance time in dusty shop environments.

LED upgrades can also be paired with controls like occupancy sensors and dimming-when the fixture and driver are compatible-to further improve efficiency.

6 Reasons to Replace Fluorescent Shop Lighting with LED

1. LED Lighting Can Significantly Reduce Energy Use

LEDs were designed for efficiency. While fluorescents are generally more efficient than older incandescent sources, many LED options outperform fluorescent systems-especially when you account for ballast draw and aging performance.

For example, a typical T8 fluorescent lamp is rated around 32W, and the ballast can add additional consumption (often estimated around 10–15%, depending on ballast type and condition). A T5HO fluorescent lamp is commonly rated around 54W, again with ballast-related overhead.

Because LED performance is best evaluated by lumens and distribution (not just watts), a proper upgrade compares the delivered light on the task plane. Many quality LED products deliver strong efficacy (lumens per watt), allowing substantial reductions in system wattage while maintaining or improving usable light.

2. LEDs Can Reduce Maintenance and Service Calls

Fluorescent systems commonly require ballast replacements, tube changes, and troubleshooting of flicker/buzzing as components age. Typical fluorescent lifespans vary widely by lamp/ballast type, usage pattern, and environment, but output and quality often degrade noticeably over time.

LED products are typically rated using L70 (the point at which output reaches 70% of initial lumens). Many commercial-grade LED fixtures and lamps are rated in the 50,000–100,000+ hour range depending on design, driver quality, and operating temperature. Note that drivers are serviceable components and may require replacement before LEDs reach end-of-life in some installations.

3. LEDs Typically Avoid Fluorescent Strobing and End-of-Life Flicker

Fluorescent fixtures are known for flicker and strobing-often made worse as lamps and ballasts age. In addition, some fluorescent systems can create audible buzzing.

LED fixtures use a driver to convert AC to regulated power for the LEDs. Quality drivers are designed to minimize visible flicker. If an LED system flickers, it may indicate a compatibility issue (for example, with a dimmer or control) or a failing driver, which is typically serviceable.

4. Fluorescent Tubes Often Contain Mercury

Most fluorescent lamps contain mercury and must be handled and disposed of according to local regulations. Broken fluorescent lamps can release mercury vapor and create glass hazards.

LED lamps generally do not contain mercury. However, LED products may still be subject to local recycling or electronics disposal rules. Always follow your local requirements for safe disposal.

5. LEDs Work Well with Occupancy Sensors

Occupancy sensors and motion controls are a strong way to improve efficiency by reducing “on” time in unoccupied areas. Frequent switching can shorten fluorescent lamp/ballast life in some scenarios, while most LED systems are well suited for occupancy-based control-provided the driver and control method are compatible.

Tip: If you plan to add controls, confirm compatibility (sensor type, wiring method, voltage, and dimming protocol) before ordering.

6. Many LED Options Support Dimming

Dimming can help optimize light levels in overly bright areas and improve energy savings-especially when paired with sensors or schedules. Many LED fixtures support dimming, commonly via 0–10V in commercial settings. Fluorescent dimming often requires specialized ballasts and lamps and can add cost and complexity.

Important: Not all LED fixtures or retrofit lamps are dimmable. Always verify dimming capability and compatibility with the intended control equipment.