Industrial facilities operate in some of the toughest conditions on earth. Every piece of equipment must perform reliably day after day to keep operations safe and productive. Yet one critical system is often overlooked until it fails: the lighting.
Lighting failure is more than a maintenance issue; it is a safety risk. OSHA identifies poor lighting as a leading cause of workplace injuries such as slips, trips, and falls. While low-cost LED fixtures may seem like a money saver, they are no match for the realities of industrial sites.
Here are seven environmental factors that can destroy your lights and how to prevent them.
1. Dust
Dust traps heat and shortens fixture life. Over time, buildup prevents proper heat dissipation and can cause premature failure. Choose IP66 or IP67-rated LEDs designed to shed debris and perform reliably at ambient temperatures up to 60°C.
2. Chemical Vapors & Volatile Organic Compounds.
Chemical vapors and volatile organic compounds (VOCs) can corrode LEDs, damage internal components, and cause color distortion. Choose hazardous-location-certified fixtures with sealed housings and chemical-resistant lenses to protect performance and ensure safety.
3. High Heat
Excessive heat from process equipment, furnaces, or motors can quickly degrade fixture components. Choose fixtures rated for ambient temperatures above 60°C, with robust thermal management systems and heat-resistant components tested for long-term reliability in extreme conditions.
4. Moisture and Corrosion
Salt spray, humidity, and corrosive chemicals can rapidly degrade fixtures and mounting hardware. Choose fixtures with sealed housings, dual powder-coated finishes, and stainless steel hardware for maximum corrosion resistance. Add secondary retention cables for an extra layer of safety.
5. Vibration
Heavy machinery and constant motion can loosen components and shake fixtures apart. Choose heavy-duty industrial LED fixtures with built-in shock resistance, rugged mechanical design, and potted drivers to prevent vibration-related failures and extend service life.
6. Flammable or Explosive Environments
In areas with explosive gases, dust, or fibers, improper lighting can pose a serious safety risk. Choose only UL, CSA, or IECEx/ATEX-certified fixtures designed for hazardous locations to prevent ignition and ensure full compliance with safety standards.
7. Unpredictable Power Conditions
Voltage spikes, surges, and drops from heavy equipment can overheat LED drivers and shorten fixture life. Choose industrial-grade fixtures with high-quality power supplies and built-in surge protection to withstand “dirty power” conditions and prevent premature failure.
Built for the Toughest Environments
Industrial facilities face some of the most demanding conditions on earth, and lighting must perform in every one of them. Understanding how dust, heat, corrosion, vibration, and power fluctuations affect fixture performance is key to maintaining safety and reliability.
At Dialight, we design LED lighting systems specifically for harsh and hazardous environments. Our fixtures undergo extensive in-house testing that far exceeds industry standards including optical testing, salt spray testing at 10x the standard, vibration and shock testing, and accelerated life testing that replicates years of exposure in extreme conditions.
With over 50 years of industrial LED lighting expertise and the largest installed base in the world, Dialight continues to set the benchmark for safety, durability, and performance in harsh and hazardous environments.