LED Lighting for Aircraft Hangars

Q: How Much Can I Save Converting My Aircraft Hangar From Metal Halide To LED Lighting?

Aircraft hangar LED conversions typically deliver 60-75% reduced energy consumption compared to metal halide systems. A typical 400W metal halide system (460W with ballast) costs $241.78 annually to operate, while a comparable 150W LED fixture costs just $78.84 annually. With 50,000+ hour lifespans , LED technology eliminate recurring lamp and ballast replacement costs that average $650 per fixture over 10 years.

Q: What Light Output Do I Need For Aircraft Maintenance Work In My Hangar?

Aircraft maintenance requires 30-50 foot candles for basic tasks and 70-100 foot candles for detailed work like drilling and riveting. Quality inspection tasks need 50-200 foot candles depending on complexity. Our Product Specialists recommend fixtures with Type 5 optics and adjustable wattage options to achieve proper light quality at your specific mounting height.

Q: Which LED High Bay Fixtures Work Best For 40-Foot Hangar Ceilings?

UFO round fixtures with 60-degree beam angles perform optimally for 40-foot ceiling heights in aircraft hangars. Our 150W to 240W UFO models deliver 22,500 to 45,600 lumens with excellent light distribution for maintenance areas. Linear fixtures work well up to 40 feet but UFO designs provide superior brightness for the large open spaces typical in aircraft hangars.

Q: Do LED Hangar Lights Qualify For Utility Rebates?

DLC Premium qualified fixtures typically qualify for utility rebates covering 30-50% of project costs in most service territories. Our fixtures meet the strict efficacy and performance standards required for rebate programs. Many utilities offer additional incentives for occupancy sensor integration, which can increase total project rebates to 60% or higher in some regions.

Q: How Long Do LED Aircraft Hangar Lights Actually Last?

Professional-grade LED hangar fixtures provide 50,000+ hours of maintenance-free operation, equivalent to 11-17 years of typical hangar use. Unlike metal halide systems that experience 30% lumen degradation in the first year, LED fixtures maintain consistent output throughout their longer lifespan . This eliminates the 2-3 year lamp replacement cycles and 5-7 year ballast replacements required with traditional systems.

Q: What Motion Sensor Options Work Best In Dusty Hangar Environments?

Microwave motion sensors provide superior reliability in dusty hangar conditions compared to PIR infrared sensors. Microwave technology penetrates dust and debris while detecting movement through materials, ensuring consistent operation. Our fixtures with integrated microwave sensors feature 1-10V dimming compatibility and can reduce maintenance by an additional 30-50% during periods of inactivity.

Q: Why Should Electrical Contractors Choose LED Lighting Supply For Hangar Projects?

LED Lighting Supply brings 15+ years of hangar lighting expertise and over 25,000 completed projects to every installation. Our Product Specialists provide consultative support beyond product sales, including complimentary photometric plans and technical guidance for optimal fixture selection. We offer direct warranty processing from our US offices and maintain extensive inventory for immediate project fulfillment, ensuring contractors meet project deadlines without delays.

Q: What Color Temperature Works Best For Aircraft Maintenance Tasks?

4000K to 5000K color temperatures provide optimal visibility for aircraft maintenance work, closely matching traditional metal halide output that maintenance crews prefer. Our color-adjustable fixtures allow selection between 3000K, 4000K, and 5000K after installation, providing flexibility to match crew preferences. 5000K delivers the brightest, most daylight-like appearance while 4000K offers comfortable working light with reduced glare .

By LED Lighting Supply

50,000+ hour LED lifespan eliminates maintenance costs and disruptions
60-75% energy savings with 1-2 year payback periods
Custom photometric plans ensure optimal illumination and coverage

Browse Our LED Lighting for Aircraft Hangars

Our commitment to quality Our products are held to the highest standards for performance & reliability LED Lighting Supply Certification Stamp

LED aircraft hangar lighting delivers the high-performance illumination essential for aviation maintenance, storage, and operational activities in facilities with challenging ceiling heights and expansive floor areas. These specialized LED Lighting Supply Aircraft Hangar Lighting solutions replace inefficient metal halide and fluorescent systems while providing superior light distribution, instant-on capability, and maintenance-free operation for decades of reliable service. Aircraft hangars demand lighting systems that can effectively illuminate both aircraft surfaces and floor work areas from mounting heights ranging from 20 to 80 feet. Our fixtures address the unique requirements of general aircraft storage, routine maintenance operations, detailed inspection work, and precision assembly tasks. Each application requires specific foot-candle levels, from 30 foot-candles for basic storage to 100+ foot-candles for quality inspection and final assembly work. The energy efficiency advantages prove substantial, with facilities typically achieving 60-75% reductions in lighting energy costs compared to traditional systems. Beyond energy savings, LED aircraft hangar lighting eliminates the recurring maintenance expenses associated with lamp and ballast replacements in high-ceiling installations. LED high bay lights designed for hangar applications provide 50,000+ hour lifespans, multiple beam angle options for optimal light distribution, and advanced control integration including motion sensors and dimming capabilities for enhanced operational efficiency in aviation facilities.

Understanding LED Aircraft Hangar Lighting Solutions

Aircraft hangars present unique lighting challenges with their vast open spaces and soaring ceilings. Our Product Specialists understand that proper lighting is critical for both safety and operational efficiency in these demanding environments. With over 15 years of experience in hangar lighting aircraft projects, LED Lighting Supply's expertise ensures you get the right solution for your specific facility needs.

Our LED high bay lights deliver the concentrated power and lumens necessary to effectively illuminate large spaces. We have found that facilities using our fixtures with 60-degree beam angle optics achieve optimal light distribution in high ceiling applications, ensuring adequate illumination reaches both aircraft surfaces and floor work areas below.

LED UFO vs Linear High Bay Infographic

Proven Benefits of LED Fixtures for Aircraft Hangar Applications

Extended Service Life	Our fixtures provide 50,000+ hours of maintenance-free operation without lamp or ballast replacements, dramatically reducing maintenance costs and operational disruptions.
Substantial Energy Cost Reductions	Customers frequently report 60% to 75% energy cost reductions compared to traditional lighting options. Adding occupancy sensors boosts savings even further, making LED hangar lights an economically smart choice.
Advanced Control Integration	We engineer high bay models with motion and occupancy sensors that automatically adjust to full power when activity is detected and dim or shut off during inactivity.
Rapid Return on Investment	Energy savings typically produce a 1–2 year payback period, with higher utility rates accelerating ROI even further.
Optimized for High-Ceiling Performance	Designed specifically for 20–80 foot ceilings, offering multiple optic packages and power levels engineered for effective light distribution and properly illuminated work environments.
Enhanced Safety and Reliability	LED fixtures maintain consistent, high-quality illumination throughout their lifespan-unlike metal halide and fluorescent systems that degrade and fail unpredictably.
Immediate Full Output	Fixtures reach 100% brightness instantly, eliminating warm-up delays associated with traditional hangar lighting.
Streamlined Installation Process	Designed for straightforward installation in both new construction and retrofit projects. Reducing electrical load often eliminates the need for electrical panel upgrades.

The U.S. Department of Energy's comprehensive research on LED lighting for commercial buildings confirms that LED technology can deliver 60-80% energy savings compared to metal halide and fluorescent systems in large-scale industrial applications like aircraft hangars.

Led Lights In Helicopter Hangar

Our 480 Watt UFO High Bay Light | 76800 Lumens High Bay fixtures delivered powerful illumination for this overseas helicopter hangar project

Industry-Standard Illumination Levels for Aviation Facilities

Our Product Specialists understand that different hangar activities require specific lighting levels to ensure safety and productivity. Based on industry standards and our extensive project experience, we recommend these illumination targets:

General Work and Storage	30 foot candles
Aircraft Maintenance with Basic Tasks	30–50 foot candles
Aircraft Maintenance with Detailed Work	70–100 foot candles
Drilling, Riveting, and Fastening Operations	75 foot candles
Final Assembly Work	100 foot candles
Quality Inspection Tasks	50–200 foot candles
Welding Operations	50 foot candles
Aircraft Storage Only	30–50 foot candles

The Illuminating Engineering Society (IES) provides comprehensive guidance on lighting standards for industrial facilities that establishes recommended illumination levels for various maintenance and operational tasks to ensure both safety and productivity in aviation facilities.

LED High Bay Mounting Height Infographic

Choosing the Right LED Hangar Lighting Solution

With over 15 years of experience, our team has identified the optimal fixture types for different hangar applications and requirements:

UFO Round Hangar Lights	Direct replacements for metal halide and HID systems. High-impact, waterproof fixtures designed for 20–80 ft ceilings. Available from 60W to 300W with multiple beam angle options.
Linear Rectangular Lights	Provide wide, even distribution for ceiling heights up to 40 ft. Ideal replacements for fluorescent and T5 systems. Available from 120W to 400W.
Dimmable LED Options	Available in UFO and linear styles with 0-10V or 1-10V dimming. Ideal for pairing with motion sensors to maximize energy savings.
Motion Sensor-Equipped Fixtures	Offered with microwave or PIR infrared sensors. Microwave sensors recommended for dusty environments due to higher reliability.
Wattage-Adjustable Solutions	Onboard switches allow wattage and lumen adjustments after installation-ideal for facilities needing flexible light levels.
Color Temperature Adjustable Lights	Selectable 3000K–5000K output. 3000K delivers warm lighting, 5000K mimics metal halide brightness, and 4000K matches fluorescent illumination.

Aircraft Hangar

We illuminated this customer's hangar using 100 / 120 / 150 / 200 Watt Adjustable UFO High Bay | 15000 to 30000 Lumens high bay fixtures.

Quantified Energy Savings and Maintenance Cost Reductions

Our hangar LED installations consistently deliver 60-75% energy savings compared to metal halide and fluorescent systems. The maintenance cost reduction proves equally impressive, with traditional metal halide fixtures requiring lamp replacement every 2-3 years and ballast replacement every 5-7 years. Our LED fixtures eliminate these recurring expenses with 50,000+ hour lifespans.

We've found that facilities using our solutions in typical 50,000 square foot hangars save $15,000-25,000 annually in combined energy and maintenance costs. The payback period typically ranges from 2-4 years, depending on local utility rates and operational patterns.

LED vs Metal Halide: Energy Savings Guide

Based on 140 hours per week operation at $0.2/kWh

60 Watt LED replaces 250W Metal Halide	Annual Energy Cost Savings: $331.24 per fixture 5-Year Savings: $1,656.20 per fixture 5-Year Savings for 20 Fixtures: $33,124.00
150 Watt LED replaces 400W Metal Halide	Annual Energy Cost Savings: $451.36 per fixture 5-Year Savings: $2,256.80 per fixture 5-Year Savings for 20 Fixtures: $45,136.00
300 Watt LED replaces 1000W Metal Halide	Annual Energy Cost Savings: $1,237.60 per fixture 5-Year Savings: $6,188.00 per fixture 5-Year Savings for 20 Fixtures: $123,760.00
600 Watt LED replaces 1500W Metal Halide	Annual Energy Cost Savings: $1,638.00 per fixture 5-Year Savings: $8,190.00 per fixture 5-Year Savings for 20 Fixtures: $163,800.00

Want to calculate your specific savings? Our Product Specialists created an LED Savings Calculator to help you determine the exact cost-effectiveness for your facility or project.

Maintenance Cost Elimination: 400W Metal Halide vs 150W LED Analysis

LED Lighting Supply's expertise ensures you understand the complete cost picture when upgrading from 400W metal halide to 150W LED fixtures. The maintenance cost reduction alone justifies the investment for most facilities.

Why Maintenance Costs Drop Dramatically

Metal Halide Maintenance Requirements	Lamp replacement every 2–3 years due to rapid lumen degradation reaching 30% within the first year Ballast replacement every 5–7 years as components fail from heat stress and electrical cycling High labor and equipment costs for accessing fixtures mounted 20–60 feet high, requiring lifts or scaffolding
LED Maintenance Requirements	No lamp or ballast replacements needed, thanks to integrated LED design with 50,000+ hour lifespans Consistent lumen output over time eliminates early replacement cycles Reduced service needs minimize lift rentals and crew downtime

10-Year Maintenance Cost Analysis Per Fixture:

Lamp Replacement Costs	400W Metal Halide: $40 × 3 cycles = $120 150W LED: $0
Ballast Replacement Costs	400W Metal Halide: $80 × 1 cycle = $80 150W LED: $0
Labor and Equipment Costs	400W Metal Halide: $150 × 3 service calls = $450 150W LED: $0
Total 10-Year Maintenance Cost	400W Metal Halide: $650 per fixture 150W LED: $0 per fixture

Result: Each 150W LED fixture saves approximately $650 in maintenance costs over a 10-year period, excluding energy savings. For facilities with 20 fixtures, this represents over $13,000 in avoided maintenance expenses.

Aircraft Hangar With Led Ufo Hbho 240 And Reflector

We used our 240 Watt UFO High Bay | 45600 Lumens fixtures to create exceptionally even and balanced lighting throughout this entire hangar space

Safety Certifications and Performance Standards

All our hangar fixtures carry essential safety and performance certifications that ensure reliable operation and often enable significant cost savings. UL Listed or ETL Listed certification guarantees electrical safety compliance, while DLC Premium qualification ensures performance standards and frequently enables utility rebates covering 30-50% of project costs.

Our fixtures feature IP65 wet location ratings for moisture resistance and IK08 impact resistance ratings, providing the durability needed in demanding hangar environments where equipment movement and maintenance activities occur regularly.

Underwriters Laboratories (UL) maintains rigorous lighting testing and certification standards that ensure electrical safety and performance reliability for commercial fixtures, while the Design Lights Consortium (DLC) establishes energy efficiency requirements that enable utility rebate programs for qualified LED lighting products.

Comprehensive 5-Year Warranty Protection

All fixtures include our standard 5-year warranty for complete confidence in your investment. We process all warranty claims directly from our United States offices, ensuring prompt resolution when service is needed. LED Lighting Supply's expertise ensures you receive responsive support throughout the entire warranty period.

Expert Consultation for Optimal Hangar Lighting Solutions

With numerous fixture options and specifications available, selecting the right solution for your specific hangar requirements can be challenging. Our Product Specialists understand the complexities of aircraft maintenance hangars and bring over 15 years of experience to every project consultation.

We engineer solutions tailored to your exact needs, facility dimensions, and operational requirements. Our team can provide you with a complimentary photometric lighting plan to ensure optimal illumination levels and balanced light distribution throughout your hangar space. Contact our hangar lighting specialists today to discuss your project and receive expert recommendations for your specific application.

Don’t Forget About the Fans

LED Lighting Supply offers both commercial and industrial HVLS fans to improve air circulation and comfort in aircraft hangars. Our HVLS fans move large volumes of air to regulate temperature, minimize humidity buildup, and reduce stagnant air pockets that can affect equipment and personnel. Commercial fans are suited for targeted airflow in maintenance or office areas, while HVLS fans provide broad, even air distribution across the hangar floor. Together, they help maintain consistent working conditions, support energy efficiency, and enhance overall air quality in large aviation environments.

Industrial HVLS Fans and Commercial Fans for Aircraft Hangars

20 Foot Diameter HVLS Ceiling Fan | 6 Blades

Common Mistakes and How to Avoid Them

I've seen the same costly errors kill hangar projects for 17 years running. Most contractors and facility managers make predictable mistakes that wreck budgets and create unsafe working conditions.

Using narrow beam angles creates dark spots between fixtures and terrible uniformity ratios. Stick with 60 to 90 degree optics for hangar applications unless you need spot lighting for specific work areas.
Mounting fixtures too close to large door openings triggers constant sensor cycling from wind and external activity. Keep motion sensors minimum 25 feet back from hangar doors or you'll get nuisance switching all day.
Undersizing wattage for ceiling height leaves mechanics working in shadows and fails inspection requirements. Need 200+ watts minimum for anything over 35 feet and 300+ watts above 50 feet.
Ignoring aircraft clearance requirements during layout puts expensive equipment at risk and creates liability issues. Factor wing span plus 8 feet minimum clearance when positioning fixtures.
Specifying 120V fixtures in 277V facilities creates expensive electrical modifications and project delays. Verify building voltage before ordering anything or you'll be buying transformers.
Installing without photometric analysis wastes money on over-lighting or under-lighting critical areas. Get the calculations done first or you're guessing on a $50,000 project.
Missing utility rebate deadlines throws away 30-40% cost savings that were sitting right there. Submit paperwork before installation starts because most utilities won't backdate approvals.

LED Lighting for Aircraft Hangars Frequently Asked Questions

How Much Can I Save Converting My Aircraft Hangar From Metal Halide To LED Lighting?

Aircraft hangar LED conversions typically deliver 60-75% reduced energy consumption compared to metal halide systems. A typical 400W metal halide system (460W with ballast) costs $241.78 annually to operate, while a comparable 150W LED fixture costs just $78.84 annually. With 50,000+ hour lifespans, LED technology eliminates recurring lamp and ballast replacement costs that average $650 per fixture over 10 years.

What Light Output Do I Need For Aircraft Maintenance Work In My Hangar?

Aircraft maintenance requires 30-50 foot candles for basic tasks and 70-100 foot candles for detailed work like drilling and riveting. Quality inspection tasks need 50-200 foot candles depending on complexity. Our Product Specialists recommend fixtures with Type 5 optics and adjustable wattage options to achieve proper light quality at your specific mounting height.

Which LED High Bay Fixtures Work Best For 40-Foot Hangar Ceilings?

UFO round fixtures with 60-degree beam angles perform optimally for 40-foot ceiling heights in aircraft hangars. Our 150W to 240W UFO models deliver 22,500 to 45,600 lumens with excellent light distribution for maintenance areas. Linear fixtures work well up to 40 feet, but UFO designs provide superior brightness for the large open spaces typical in aircraft hangars.

Do LED Hangar Lights Qualify For Utility Rebates?

DLC Premium qualified fixtures typically qualify for utility rebates covering 30-50% of project costs in most service territories. Our fixtures meet the strict efficacy and performance standards required for rebate programs. Many utilities offer additional incentives for occupancy sensor integration, which can increase total project rebates to 60% or higher in some regions.

How Long Do LED Aircraft Hangar Lights Actually Last?

Professional-grade LED hangar fixtures provide 50,000+ hours of maintenance-free operation, equivalent to 11-17 years of typical hangar use. Unlike metal halide systems that experience 30% lumen degradation in the first year, LED fixtures maintain consistent output throughout their lifespans . This eliminates the 2-3 year lamp replacement cycles and 5-7 year ballast replacements required with traditional systems.

What Motion Sensor Options Work Best In Dusty Hangar Environments?

Microwave motion sensors provide superior reliability in dusty hangar conditions compared to PIR infrared sensors. Microwave technology penetrates dust and debris while detecting movement through materials, ensuring consistent operation. Our fixtures with integrated microwave sensors feature 1-10V dimming compatibility and can reduce energy consumption by an additional 30-50% during periods of inactivity.

Can I Install LED Hangar Lights On Existing Electrical Circuits?

Energy efficient LED fixtures typically reduce electrical load by 67-74% compared to metal halide systems, allowing multiple LED fixtures on existing circuits designed for fewer traditional fixtures. Most installations can utilize existing electrical infrastructure without panel upgrades. However, we recommend electrical load calculations to optimize circuit utilization and ensure UL Listed installation compliance.

Why Should Electrical Contractors Choose LED Lighting Supply For Hangar Projects?

LED Lighting Supply brings 15+ years of hangar lighting expertise and over 25,000 completed projects to every installation. Our Product Specialists provide consultative support beyond product sales, including complimentary photometric plans and technical guidance for optimal fixture selection. We offer direct warranty processing from our US offices and maintain extensive inventory for immediate project fulfillment, ensuring contractors meet project deadlines without delays.

What Color Temperature Works Best For Aircraft Maintenance Tasks?

4000K to 5000K color temperatures provide optimal visibility for aircraft maintenance work, closely matching traditional metal halide output that maintenance crews prefer. Our color-adjustable fixtures allow selection between 3000K, 4000K, and 5000K after installation, providing flexibility to match crew preferences. 5000K delivers the brightest, most daylight-like appearance while 4000K offers comfortable working light with reduced glare.

How Do I Calculate The Right Number Of LED Fixtures For My Hangar Size?

Hangar fixture requirements depend on ceiling height, desired foot candle levels, and fixture lumen output. A typical 50,000 square foot hangar with 40-foot ceilings requires 20-30 fixtures in the 200-300W range for adequate maintenance lighting. Our Product Specialists provide complimentary photometric lighting plans that specify exact fixture quantities, spacing, and mounting locations to achieve uniform illumination throughout your facility and outdoor hangar areas.

What Safety Certifications Should I Look For In Hangar LED Fixtures?

Essential certifications include UL Listed or ETL Listed for electrical safety, DLC Premium for energy efficiency, and IP65 ratings for moisture resistance. Aircraft hangar fixtures should also carry IK08 impact resistance ratings to withstand equipment movement and maintenance activities. These certifications ensure reliable operation despite temperature fluctuations and often enable significant utility rebates covering 30-50% of project costs.

Why Do Facility Managers Choose LED Lighting Supply For Commercial Hangar Upgrades?

Facility managers select LED Lighting Supply for our proven track record of 25,000+ successful installations and comprehensive project support from planning through warranty service. Our consultative approach includes energy analysis, rebate assistance, and ongoing technical support that extends far beyond product delivery. With 5-year warranty protection processed directly from our US offices, managers receive the responsive service and reliability needed for efficient operations.

LED Lighting for Aircraft Hangars

UFO Round Lights for Hangars

LED Linear Rectangular Lights for Hangars

HVLS Fans | Industrial Ceiling Fans

High Power Flood Lights