We've seen lighting installed first, racking added later, and forklifts struggling to read pallet labels because the fixtures sit between aisles instead of above them. We've also seen High Bay lights positioned beautifully for an empty warehouse, then completely blocked by VNA uprights once the racks go in. After two decades of fabricating and installing racking for Singapore warehouses, 3PLs, and factories, we've learned that lighting and racking need to be coordinated before either system is finalised — not retrofitted afterward.

This article walks through what we check, coordinate, and flag during the design phase so that your warehouse lighting actually works with your racking layout, not against it.

Why Lighting and Racking Need to Be Planned Together

Racking changes how light moves through a warehouse. Uprights cast shadows. Beams interrupt sightlines. Top-level pallets block downward throw from High Bay fixtures. And aisles — especially narrow ones in VNA or Double-Deep layouts — create canyon-like corridors where light doesn't naturally reach unless fixtures are positioned with the aisle orientation in mind.

We see three common scenarios where poor coordination creates problems:

• Fixtures positioned for an open floor plan, then racks added later — lights end up between aisles instead of above them, creating dark corridors where operators pick or move pallets.
• Beam heights not shared with the lighting designer — High Bay fixtures mounted too low, leaving insufficient clearance for top-level loads or forklift mast travel.
• Lux requirements treated as uniform — the same lighting intensity applied to bulk storage zones and active picking faces, wasting energy or under-lighting critical areas.

When we quote a racking project, we ask if the lighting is already installed, planned, or still open. If it's still open, we share our proposed aisle orientations, beam heights, and upright spacing early so the lighting contractor or M&E consultant can design around the real layout, not a blank floor.

What We Coordinate Before Steel Arrives

Aisle Orientation and Fixture Alignment

Aisles run in one direction. Fixtures need to be centred above them, not offset between rows. This sounds obvious, but it only works if the lighting designer knows where the aisles will be before conduit is run and brackets are mounted.

We provide a CAD plan showing:

• Aisle centrelines and widths (for Selective, VNA, or Drive-In configurations)
• Upright frame positions (which create the vertical shadow-casters)
• Cross-aisle spacing (relevant for forklift turning zones, where light throw matters more)

For VNA and Narrow Aisle layouts, this is especially critical. Aisles are often 1,650–1,800 mm wide, and if the High Bay fixture is even 500 mm off-centre, one side of the aisle ends up in shadow while the other is over-lit.

Beam Heights and Fixture Mounting Clearance

We dimension our racks to the pallet load, the forklift mast, and the clear height available under the roof or services. But that "clear height" needs to account for lighting fixtures, conduit runs, and any pendant-mount High Bays.

Before we finalise beam elevations, we ask:

• What is the lowest point of the proposed lighting fixture (including bracket, pendant, or surface mount)?
• Does the client need clear mast travel above the top beam, or will the top level be block-stacked and accessed by order picker only?
• Are there sprinkler heads, HVAC ducts, or cable trays that also eat into overhead clearance?

We've had projects where the lighting designer assumed 9 m clear height, but after accounting for 800 mm High Bay pendants and 400 mm of service buffer, the real available height for the top beam was 7.8 m. That's a whole pallet level lost if no one checks early.

Shadow Zones and Upright Frame Spacing

Upright frames are typically 75–100 mm deep (front-to-back). They don't sound like much, but when you have a row of them every 2.4–3.0 m along a 40 m aisle, and the light source is 8–10 m above, the cumulative shadow effect is real — especially at the lower beam levels where operators are picking.

We can't eliminate shadows, but we can minimise them by:

• Aligning fixture spacing with upright bay spacing, so shadows fall predictably (and operators know where to expect them)
• Using higher-lux fixtures in active picking zones (e.g., 300 lux at floor level) and lower-lux fixtures in bulk/reserve zones (e.g., 150 lux)
• Recommending aisle-mounted LED strips or task lighting for ground-level picking faces in VNA or man-up order picker setups

Some clients assume one High Bay every 100 m² is enough. In a racked environment, that might leave the bottom two beam levels under-lit unless supplementary fixtures are added at mid-height or aisle level.

Lux Zoning by Function

Not all warehouse zones need the same light. We work with clients to map lighting intensity to activity:

• Active picking faces — 300–400 lux at pallet height, so labels, barcodes, and product ID are clearly visible
• Bulk/reserve storage (Drive-In, block stack) — 150–200 lux, sufficient for safe forklift movement and stock checks
• Cross-aisles and marshalling zones — 200–250 lux, enough for safe navigation and pallet staging
• Receiving/dispatch bays — 300–500 lux, often higher because this is where QC, labelling, and sortation happen

We share this functional breakdown with the lighting designer so fixture counts, wattages, and mounting heights can be tailored. It avoids over-lighting (which wastes energy and creates glare) and under-lighting (which slows operations and increases picking errors).

Emergency Lighting and Exit Path Visibility

BCA and SCDF require emergency egress lighting in industrial buildings, and racking layouts affect where exit paths run. If your racks create long aisles with no cross-access for 30+ metres, you may need additional emergency fixtures or illuminated exit signage at aisle ends.

We flag this during layout design, especially for mezzanine projects (where we're already coordinating SCDF submissions). If the mezzanine includes racking on the upper level, the lighting plan needs to account for egress routes on both levels, with clear visibility from any point in the racked area to the nearest exit.

We don't design the emergency lighting ourselves — that's the M&E consultant's scope — but we provide the rack elevations, aisle widths, and mezzanine access points so the emergency lighting plan reflects the real circulation pattern, not an open floor assumption.

When We Get Involved

Ideally, we're brought in during the warehouse fit-out design phase, before the lighting contractor has run conduit or mounted fixtures. That gives us the chance to share our proposed layout, check fixture clearances, and coordinate aisle alignment.

If the lighting is already installed, we work within the existing grid. We've done plenty of retrofits where we adapt our aisle orientations or bay depths to suit the fixture positions — but it's always a compromise. You might end up with slightly narrower aisles, or fewer beam levels, or a layout that's less efficient than it could have been if both systems were planned together.

If you're planning a new warehouse, an expansion, or a full refit, bring your racking supplier and your lighting designer into the same conversation early. We'll share our CAD plan, they'll overlay their fixture grid, and we'll iterate until both systems work together.

What We Don't Do

We don't design or install lighting. We're a racking fabricator and installer. Our role is to provide the dimensional and functional information that the lighting designer needs to do their job well.

If you don't have a lighting designer yet, we can refer you to M&E consultants or contractors we've worked with on past projects. We've coordinated lighting on hundreds of warehouse and mezzanine installs across Singapore — Tuas, Woodlands, Jurong, Changi — and we know which trades need to talk to each other, and when.

Common Mistakes We Help Clients Avoid

• Installing lighting first, racking second — locks you into a fixture grid that may not align with your final aisle layout.
• Assuming "High Bay = solved" — High Bays are great for general illumination, but racked aisles often need supplementary task lighting at lower levels.
• Not checking fixture clearance against top beam height — results in lost pallet positions or unsafe clearance for forklift masts.
• Using the same lux everywhere — wastes energy in bulk zones and under-lights picking faces.
• Not coordinating with SCDF requirements for mezzanines — emergency lighting and exit signage need to be designed around racking and egress routes, not added as an afterthought.

Our Process

When you engage us for a racking project, here's how we coordinate lighting:

1. Site survey — we measure the space, check existing lighting positions (if any), note ceiling height, services, and any obstructions.
2. Preliminary layout — we draft a racking plan based on your pallet count, SKU mix, and forklift fleet, and share it with you and your lighting designer (if appointed).
3. Coordination meeting — we walk through aisle orientations, beam heights, and functional zones, and flag any clearance or shadow concerns.
4. Final layout — we lock in the racking design; the lighting designer finalises fixture positions, and both plans are issued for installation.
5. Installation — we fabricate and install the racking; the lighting contractor installs fixtures. If there's a clash on-site (rare, but it happens), we coordinate the adjustment in real time.

We've done this hundreds of times. The more you involve both trades early, the fewer surprises you get on-site.

Frequently Asked Questions

Do you install warehouse lighting as part of your racking projects?

No, we don't install lighting — we're racking fabricators and installers. But we coordinate closely with your lighting contractor or M&E consultant to ensure fixture positions, clearances, and aisle alignment work with the racking layout. If you don't have a lighting partner yet, we can refer contractors we've worked with on past projects.

What happens if the lighting is already installed before we engage you for racking?

We work within the existing fixture grid. We'll adapt our aisle orientations and bay spacing to suit the lighting layout as best we can, but it's always a compromise — you may end up with fewer beam levels, narrower aisles, or less efficient space use than if both systems were planned together. If possible, we recommend coordinating racking and lighting before either is installed.

How much clearance do you need between the top beam and warehouse lighting fixtures?

It depends on your forklift and load height. For standard counterbalance or reach truck operations, we typically allow at least 300–500 mm clearance between the top of the loaded pallet and the lowest point of the light fixture (including bracket or pendant). For VNA or man-up order pickers, we need to check the mast's extended height and add buffer for safe travel. We flag this during the site survey and layout design phase.

Can you recommend lux levels for different areas of a racked warehouse?

We're not lighting designers, but based on two decades of warehouse projects, here's what we typically see and coordinate around: 300–400 lux for active picking faces, 150–200 lux for bulk storage or Drive-In zones, 200–250 lux in cross-aisles, and 300–500 lux in receiving or dispatch bays. The exact levels depend on your operation, SKU visibility requirements, and whether you're doing manual picking or relying on barcode scanners. We share these functional zones with your lighting designer so they can tailor the fixture plan accordingly.

Do lighting and racking need to be coordinated for SCDF submissions on mezzanine projects?

Yes. SCDF requires emergency egress lighting, and the layout of your racking affects where exit paths run and where emergency fixtures need to be positioned. If you're installing racking on a mezzanine level, the lighting plan needs to account for both the mezzanine deck and the racked aisles, with clear visibility to exits. We coordinate this as part of our mezzanine submission process — we provide the architectural and structural drawings (including racking layout), and the M&E consultant provides the lighting and fire protection plans. Both get submitted together to SCDF.

Get It Right the First Time

We've fixed enough lighting-and-racking mismatches to know that coordination saves time, money, and frustration. If you're planning a new warehouse fit-out, expanding an existing facility, or adding racking to a space where lighting is already in place, let's talk early. We'll share our layout, check the clearances, and make sure your lights and your steel work together.

Drop us a message and we'll walk you through the coordination process: https://wa.me/6591072601