LED High Mast Lights

LED High Mast Lighting Solutions for Large-Scale Commercial Applications

LED Lighting Supply's high mast fixtures are engineered for expansive commercial and industrial areas needing powerful illumination from extreme heights. Our Product Specialists design each high mast fixture to accommodate 4 to 16 individual lights, depending on your coverage and pole requirements.

With over 15+ years of experience in commercial LED lighting, we offer high mast fixtures from 450 to 750 watts, replacing 1000 to 2000 watt metal halide systems and achieving 50% to 70% energy reduction. For metal halide replacement, 5000K is common for crisp, neutral-white light and visibility in large outdoor work zones. Where glare or spill is a concern, 4000K may be preferred.

According to the U.S. Department of Energy's LED lighting guidance, LED technology can reduce energy consumption by 75% or more compared to traditional lighting like metal halide and high-pressure sodium. The DOE notes that LED fixtures provide superior outdoor and industrial performance with significant long-term cost savings through reduced energy and maintenance.

LED Lighting Supply's expertise ensures optimal performance through detailed lighting plans that select the proper optic configuration for each application. This approach maximizes coverage and eliminates costly dark spots or over-illumination.

Our High Mast LED Lights installed in Washington State deliver reliable performance

Why LED High Mast Fixtures Outperform Traditional Metal Halide Systems

Our Product Specialists recognize the performance advantages that make LED high mast lighting the economical choice for large-scale applications. Facilities using our LED high mast fixtures consistently achieve measurable improvements across multiple operational areas.

• Proven Energy Savings: Solutions deliver 50% to 70% reduction in electrical costs. LEDs convert more electricity into visible light with less wasted as heat, creating ongoing savings.
• Direct Retrofit Capability: Fixtures provide one-for-one replacement of metal halide with minimal rewiring or structural changes (often mount-compatible; verify onsite). Multiple lumen packages ensure light output matches your requirements when properly specified.
• Streamlined Installation Process: Standard 2 3/8" pipe mounts connect directly to existing hardware. Most installations are completed in half the time of traditional fixture replacements.
• Reduced Light Pollution: Precision optics direct light downward, minimizing upward spill and improving ground-level visibility for safety.
• Dramatically Reduced Maintenance: Fixtures operate for 50,000+ hours compared to 15,000 hours for metal halide bulbs, reducing bulb and ballast replacements and crane rental costs.
• Extreme Weather Durability: IP66 rating provides dust and water protection, while IK08 impact rating withstands severe mechanical impacts. Fixtures survive harsh weather that damages traditional lighting.
• Superior Light Quality for Safety: LED color rendering reveals true colors in work areas, improving safety and productivity over high-pressure sodium lights.
• Instant Operation: Full brightness within seconds of power-on, unlike traditional fixtures that require 15-20 minutes to reach full output. This immediate response improves security and efficiency.

What are the Cost Savings and ROI When You Convert from Metal Halide to LED?

450W LED High Mast Light vs 1000W Metal Halide Replacement (with ballast)

Assumptions: Based on 12 hours/day, 365 days/year at $0.16/kWh, 50 fixture(s), and a 15% ballast factor applied to the metal halide wattage (1000W lamp + 15% ballast = ~ 1,150W input).
•  Energy cost and ROI calculations are based on energy savings only and assume an LED fixture cost of $1,355.00 per fixture.
• Maintenance savings from reduced bulb and ballast replacements are not included in these calculations.

In this example with 50 fixture(s), total LED fixture investment is approximately $67,750.00, and estimated annual energy-only savings are $24,528.00. Simple payback based on energy savings alone is under 34 months. Maintenance savings from eliminating metal halide bulb and ballast replacements provide additional value throughout the fixture's 50,000-hour lifespan, but are not included in this ROI calculation.

Engineering & Safety Disclaimer (Read Before Finalizing a Design)

This information is provided for general planning purposes only. Final fixture selection, structural suitability, and installation methods must be verified by qualified professionals based on site-specific conditions. High mast projects may require engineering review for wind load / EPA (effective projected area), pole and anchor condition, mounting hardware ratings, electrical distribution, and local code requirements. Always follow the manufacturer's installation instructions and your local government authority requirements.

Optimal Applications for LED High Mast Lighting Solutions

• Shipyards: Require powerful illumination covering massive work areas. Wide beam angle configurations illuminate multiple ship sections while providing true color rendering for fabrication and repair.
• Rail Yards: Demand reliable lighting for continuous 24/7 operations. LED durability eliminates costly maintenance delays that disrupt transportation and cargo handling.
• Large Open-Area Storage Facilities: Benefit from uniform coverage across expansive ground areas. Even light improves worker safety, operator visibility, and reduces liability.
• Prison Facilities: Require uninterrupted security lighting. Instant-on LED technology prevents dark periods during power cycling or emergencies.
• Power Generation Plants: Need perimeter security lighting that operates reliably in harsh environments. Fixtures withstand vibration and temperature extremes.
• Security Applications: Benefit from integrated motion detection. Automated controls reduce energy use while maintaining security coverage.
• Container Yards: Require precise color rendering for safe equipment operation. True white LED illumination improves operator visibility and safety during loading and unloading.
• Large Parking Areas: Need broad coverage with minimal pole requirements. High-output fixtures reduce installation costs by covering larger areas per fixture while meeting IESNA standards when properly specified.
• Highways: Especially interchanges, benefit from powerful high mast lighting.

Designers often reference IES recommended practices for high mast lighting. These guidelines define proper illumination levels, uniformity ratios, and distribution patterns to ensure visibility and safety in large-area applications.

Selecting the Right LED High Mast Solution for Your Application

Our Product Specialists know different applications require specific control and performance features. We offer solutions tailored to operational requirements.

• Dusk to Dawn High Mast Lights: Integrated photocell sensors automatically activate lights at dusk and deactivate at dawn, ensuring proper operation without manual intervention.
• Motion Sensor High Mast Lights: Advanced motion sensors dim lights to 20% output when unoccupied, then instantly return to full brightness when motion is detected.
• 1000 to 2000 Watt HID Equivalent Performance: Fixtures produce 69,750 to 112,500 lumens each, providing direct replacement for high-intensity discharge systems when properly specified.
• High Voltage Compatibility: Fixtures include 277-480 volt LED drivers that adjust to your facility's electrical system, handling both single-phase and 3-phase installations.

Professional Installation and Design Recommendations

With over 15+ years of LED lighting experience, LED Lighting Supply's expertise ensures optimal configuration selection based on real-world performance data. We stock all common mounting options, with 2 3/8" pipe mount being the most frequently requested configuration.

Our customers report that LED fixtures significantly reduce amp load, often eliminating the need to upgrade electrical panels when converting from traditional lighting. Facilities using 5000K color temperature achieve optimal visibility, while Type III or Type V beam angles provide superior coverage for most applications.

Structural Verification: Wind Load / EPA and Pole Condition

High mast retrofits should include a structural suitability check. Confirm the pole, anchor base, and mounting hardware are appropriate for the fixture array, including EPA (effective projected area), local wind speed requirements, and any site-specific exposure conditions. If you are replacing older HID arrays, note that LED fixture dimensions and wind profile may differ from the original system.

Professional Lighting Design Services

LED Lighting Supply's expertise includes comprehensive lighting design services that ensure optimal performance and regulatory compliance. We create detailed photometric lighting plans using professional lighting software that imports your facility layout to generate precise illumination analysis.

Our lighting plans show exact light levels, uniformity ratios, and identify which fixture configurations create optimal coverage while meeting IESNA standards. We provide complimentary lighting plans for commercial, industrial, and security applications to ensure proper illumination levels while avoiding costly over-lighting or dangerous under-lighting conditions.

What We Need to Build an Accurate High Mast Lighting Plan

• Site type: port, rail yard, container yard, parking, roadway/interchange, security perimeter, etc.
• Pole details: mounting height, quantity, spacing, and existing headframe/arm configuration
• Mounting hardware: tenon size (commonly 2 3/8"), bolt pattern, and allowable fixture weight
• Wind / structural constraints: required wind rating and any known pole engineering limits (EPA, anchor condition)
• Electrical: available voltage (e.g., 277V, 480V), phase, and control wiring availability
• Performance goals: target foot-candles, uniformity expectations, glare/spill constraints, and operating hours
• Controls: photocell, motion dimming profile, 0-10V, scheduling, or networked controls (if applicable)

Tip: If you can share a site plan or aerial screenshot with approximate pole locations and dimensions, we can turn around a more accurate photometric layout and fixture schedule.

Safety Certifications and Performance Standards

High mast applications often require third-party verification for safety, performance, and rebate eligibility. Certification availability varies by fixture series and configuration, so always verify on spec sheet the exact listing and documentation for the model you are specifying.

• UL Listed or ETL Listed (electrical safety compliance)
• DLC Premium or DLC Listed (efficiency/performance qualification for many rebate programs, where applicable)
• IP ratings (ingress protection for dust/water exposure based on environment)
• IK impact ratings (mechanical durability based on fixture construction)

The Design Lights Consortium (DLC) Qualified Products List and UL lighting resources can help validate product listings when documentation is required for rebates, bids, or compliance review.

Comprehensive Warranty Protection and USA-Based Support

LED Lighting Supply's expertise includes comprehensive warranty protection with all fixtures backed by at least a 5-year warranty supported by our USA-based customer service team. Our experienced support specialists understand the critical importance of maintaining operational lighting systems and work efficiently to resolve any warranty issues.

Expert Consultation for High Mast Lighting Projects

Our Product Specialists understand that selecting the optimal high mast lighting solution requires careful analysis of multiple technical and operational factors. LED Lighting Supply's sales engineers specialize in large-scale LED lighting applications and provide consultative guidance to ensure proper system selection.

We need to understand your specific motion sensor or photocell requirements, current voltage specifications, and any unique mounting constraints your facility presents. Our team provides complimentary professional lighting plans to ensure proper illumination levels and balanced light distribution across your entire coverage area.

Request a quote from our LED lighting specialists today to discover how our high mast solutions can reduce your energy costs while improving safety and operational efficiency.

Common Mistakes and How to Avoid Them

High mast projects present unique challenges, but contractors commonly make the same expensive mistakes. Wind loading calculations get ignored, beam angles get mismatched with mounting heights, and surge protection gets skipped until lightning takes out half the installation.

• Ignoring Photometric Data: Selecting fixtures based on wattage instead of beam distribution patterns and actual lumen output. Check coverage area compatibility before placing orders.
• Mismatched Beam Angles: See beam angle guidance in the Professional Installation section above for proper height matching.
• Skipping Structural Analysis: See EPA/wind load guidance in the Structural Verification section above for proper engineering review requirements.
• Missing Surge Protection: One lightning strike destroys expensive LED drivers across multiple fixtures.
• No Pilot Testing: Install two or three units to verify coverage before committing to the entire project.
• Voltage Mismatches: 277V, 347V, and 480V aren't interchangeable - verify electrical compatibility.
• Poor Installation Timing: Schedule crane work during off-peak operations with proper safety planning and clear zones.

LED High Mast Lights Frequently Asked Questions

What wattage LED fixture replaces a 1000-2000 watt metal halide high mast light?

450-750 watt LED fixtures replace 1000-2000 watt metal halide systems, delivering 50-70% energy reduction while maintaining equivalent light output when properly specified.

What beam angle should I use for high mast lighting at different mounting heights?

15-degree optics require 60+ foot pole heights, while 90-degree beams work at 30-40 feet. Verify beam angle and mounting height compatibility before ordering.

How many individual lights can a single high mast unit accommodate?

Each high mast unit accommodates 4-16 individual lights depending on coverage requirements and pole specifications.

What voltage options are available for LED high mast fixtures?

Fixtures include 277-480 volt LED drivers that handle both single-phase and 3-phase installations. Confirm your facility''s electrical system voltage before ordering.

What mounting hardware is standard for LED high mast installations?

Most installations use 2 3/8" pipe mounts compatible with existing hardware. Verify onsite compatibility before finalizing your order.

What color temperature is best for high mast lighting applications?

Use 5000K for optimal visibility in work zones. Where glare sensitivity or adjacent residential spill is a concern, 4000K may be preferred.

What control options are available for LED high mast lights?

Options include dusk-to-dawn photocells for automatic operation and motion sensors that dim to 20% when areas are unoccupied, then return to full brightness when motion is detected.

What protection ratings should I look for in high mast fixtures?

IP66 rating provides complete dust protection and high-pressure water resistance. IK08 impact rating withstands severe mechanical impacts in harsh environments.

What applications are LED high mast lights designed for?

High mast fixtures illuminate large coverage areas from extreme heights including shipyards, rail yards, container yards, parking areas, prison facilities, and power generation plants requiring 24/7 operations with minimal maintenance.

When should I NOT use LED high mast lighting?

Avoid high mast fixtures when mounting heights are under 30 feet where standard area lighting is more cost-effective, when structural limitations exist without engineering review of wind load/EPA and pole condition, or when precise task lighting is needed rather than area illumination.

What structural verification is required before installing LED high mast fixtures?

Verify wind load/EPA and pole structural condition before ordering - LED fixture arrays may have different wind profiles than original HID systems. Final selection should be validated with a photometric plan and confirmed by a licensed professional when required.

What lumen output do LED high mast fixtures provide?

High mast fixtures produce 69,750 to 112,500 lumens each, providing direct replacement capability for 1000-2000 watt HID systems when properly specified.

How long do LED high mast fixtures last compared to metal halide?

LED fixtures operate for 50,000+ hours compared to 15,000 hours for metal halide bulbs, subject to site conditions.

What warranty coverage is provided with LED high mast fixtures?

All fixtures are backed by at least a 5-year warranty supported by USA-based customer service.

What certifications should I verify for LED high mast fixtures?

Verify UL Listed or ETL Listed for electrical safety, and DLC Premium or DLC Listed for rebate eligibility where applicable. Certification availability varies by fixture series - verify on the spec sheet for the specific model.

Why is surge protection important for high mast LED installations?

Lightning strikes destroy expensive LED drivers. Budget constraints that prevent proper surge protection create significant risk for high mast installations.

What information is needed to create an accurate high mast lighting plan?

Provide pole details (mounting height, quantity, spacing), electrical specifications (voltage, phase), target foot-candles, and any wind/structural constraints including EPA limits and anchor condition.