Heavy Industrial &
High Temperature
LED Lighting
INS-D series: purpose-built for steel mills, foundries, forges, and 65°C+ extreme environments. IP66 + IK10 protection meets the demands standard fixtures cannot survive.
120,878 lm
Up to (720W)
IP66+IK10
Extreme Protection
170 lm/W
DLC Premium
Why Standard Fixtures Fail in High Temperature Environments
Standard LED fixtures are rated for 25–50°C ambient. In steel mills, foundries, and forges operating at 65°C+, every component is pushed beyond its design limits.
Driver Overheating
Standard LED drivers are rated for 50°C ambient. In steel mills and foundries at 65°C+, drivers degrade rapidly — capacitor life halves with every 10°C increase.
INS-D Solution:
INS-D uses specially rated high-temperature drivers designed for continuous operation at 65°C+ ambient.
Seal Failure
IP65 is insufficient. Repeated thermal expansion/contraction at extreme temperatures breaks standard gaskets, allowing dust and moisture infiltration.
INS-D Solution:
INS-D features high-temperature silicone gaskets and IP66 rating — dust-tight plus resistance to powerful water jets.
Accelerated Lumen Depreciation
For every 10°C increase in ambient temperature, LED lifespan is cut in half. A fixture rated for 50,000 hours at 25°C may last only 12,500 hours at 45°C.
INS-D Solution:
INS-D aluminum alloy heat sink maintains junction temperatures within spec even in 65°C+ environments. L90B10 rated at 100,000 hours.
Lens Warping & Yellowing
Standard polycarbonate lenses deform and yellow under sustained high temperatures, reducing light transmission by 20–40% within a year.
INS-D Solution:
INS-D uses heat-resistant optical materials that maintain clarity and beam precision over the full fixture lifetime.
INS-D Technical Highlights
315W–720W High Bay for High Temperature Environments
170 lm/W
Industry-leading efficacy
IP66 + IK10
Extreme dust, water & impact protection
Lumileds Chips
Premium LED source for reliability
15° / 30° / 60° / 120°
Four beam angle options
Ra70 / Ra80 / Ra90
CRI options for every application
100-277V / 277-480V
Dual voltage range
0-10V Dimming
Smooth dimming control
L90B10 100,000 hrs
90% lumen maintenance
5-Year Warranty
Extendable to 10 years
IES RP-7-21 Heavy Industrial Illuminance Standards
Recommended foot-candle levels and CRI requirements by heavy industrial zone
Steel mill — general production
Extreme heat, dust, IP66 required
Foundry — pouring & molding
Molten metal glare, high ambient temp
Forge — hammer & press area
Extreme vibration + heat
Heat treatment furnace area
65°C+ ambient, thermal cycling
Welding shop
General ambient only (task light separate)
Quality inspection
Color-critical surface inspection
Glass manufacturing
High radiant heat, clear optics required
Cement / concrete plant
Extreme dust, IP66 mandatory
Power generation (turbine hall)
High ceilings 40–80ft, vibration
Automotive mega-factory
Large span, mixed heights 30–60ft
Material handling / crane bay
Overhead crane clearance
Maintenance & tool room
Precision tasks
Source: ANSI/IES RP-7-21 (Recommended Practice for Industrial Lighting). Always verify with local AHJ and facility safety officer.
INS-D Selection Guide by Ceiling Height
Match your mounting height to the optimal INS-D wattage and beam angle configuration
25–35 ft
35–50 ft
50–70 ft
70–100ft+
Compliance & Regulatory Requirements
Key U.S. standards for heavy industrial facility lighting design
OSHA 29 USC 654
General duty — safe illumination
Federal requirement
IES RP-7-21
Industrial facility recommended practice
Authoritative design standard
NFPA 70 (NEC)
Electrical code, Class I/II division considerations
Fixture wiring & circuiting
NFPA 13
Sprinkler clearance 18″ minimum
Mounting height constraint
UL 1598
Listed luminaire — INS-D ✅
All Auvolar fixtures ✅
IP66 (IEC 60529)
Dust-tight + powerful water jet protection
INS-D ✅
IK10 (IEC 62262)
20 joule impact resistance
INS-D ✅
DLC Premium
Highest tier utility rebate eligibility
INS-D ✅
ASHRAE 90.1-2022
Energy code — occupancy + daylight controls
New construction
IEEE 1789
Flicker-free for rotating machinery safety
Critical for heavy industry
Lighting Solutions by Heavy Industrial Scenario
Design parameters, example configurations, and recommended INS-D setups for each extreme environment
🔥 Steel Mill & Smelting
The most extreme industrial lighting environment. Electric arc furnaces, continuous casting, and rolling mills generate ambient temperatures exceeding 65°C with extreme airborne dust and particulate. Ceiling heights range 40–60 ft. Standard fixtures fail within months — drivers overheat, seals degrade, and lenses warp. IP66 dust-tight construction and heat-rated drivers are absolute requirements.
Design Parameters
| Target illuminance | 30–50 fc |
| Min illuminance | 20 fc |
| CRI | ≥70 general, ≥80 inspection |
| Ceiling height | 40–60 ft |
| Beam angle | 15°–30° narrow beam |
| Special | IP66 mandatory, heat-rated drivers, extreme dust |
Example Configuration
Recommended Products
🏭 Foundry & Casting
Foundry environments expose fixtures to radiant heat from molten metal, intense glare from pouring operations, and heavy particulate from sand casting. Ambient temperatures near furnaces regularly exceed 55°C. Fixtures must withstand thermal shock from rapid temperature swings. IP66 sealing prevents molten splash damage and dust ingress that degrades optical performance.
Design Parameters
| Target illuminance | 50–100 fc |
| Min illuminance | 30 fc |
| CRI | ≥70 general, ≥80 QC areas |
| Ceiling height | 35–50 ft |
| Beam angle | 30°–60° |
| Special | IP66 mandatory, radiant heat resistant |
Example Configuration
Recommended Products
🔨 Forge & Heat Treatment
Forging presses and drop hammers generate extreme vibration that loosens connections and cracks standard housings. Heat treatment furnaces cycle between ambient and 65°C+ repeatedly, causing thermal fatigue on seals and drivers. IK10 impact resistance is essential for flying debris protection. Fixtures must survive continuous thermal cycling without seal degradation.
Design Parameters
| Target illuminance | 20–50 fc |
| Min illuminance | 10–20 fc |
| CRI | ≥70 |
| Ceiling height | 25–40 ft |
| Beam angle | 60°–120° |
| Special | IK10 impact, thermal cycling, vibration rated |
Example Configuration
Recommended Products
🚗 Automotive Mega-Factory
Tesla Gigafactory-scale operations span 1M+ sq ft with mixed ceiling heights from 30–60 ft across welding, paint, assembly, and warehousing zones. Each zone has different illuminance and CRI requirements. Welding areas need ambient lighting only (30–50 fc, CRI ≥70), while final inspection demands 100+ fc with CRI ≥90. A single high-output fixture platform simplifies procurement and maintenance across all zones.
Design Parameters
| Target illuminance | 50–100 fc (zone dependent) |
| Min illuminance | 30 fc |
| CRI | ≥80 general, ≥90 paint/inspection |
| Ceiling height | 30–60 ft mixed |
| Beam angle | 15°–60° (zone matched) |
| Special | Multi-zone, single platform, 0-10V dimming |
Example Configuration
Recommended Products
🏗️ Glass & Cement Manufacturing
Glass furnaces produce intense radiant heat that warps standard PC lenses and yellows optical components. Cement plants generate the most aggressive airborne dust in any industrial setting — fixtures without IP66 rating clog within weeks, losing 40–60% light output. Both environments demand sealed optics that maintain transmission clarity and fixtures that resist thermal degradation over years of operation.
Design Parameters
| Target illuminance | 20–75 fc (zone dependent) |
| Min illuminance | 10–30 fc |
| CRI | ≥70 cement, ≥80 glass |
| Ceiling height | 35–55 ft |
| Beam angle | 30°–60° |
| Special | IP66 dust-tight mandatory, heat-resistant optics |
Example Configuration
Recommended Products
Recommended Products for Heavy Industrial Facilities
IP66 rated, heat-resistant, DLC Premium certified LED fixtures for extreme environments
LED vs Traditional: Energy Savings Comparison
Based on $0.12/kWh, 6,000 hrs/year (heavy industrial two-shift operation)
1000W Metal Halide → INS-D 460W
1500W Metal Halide → INS-D 720W
400W HPS → INS-D 315W
1000W HPS → INS-D 580W
2000W Metal Halide → INS-D 720W ×2
💰DLC Premium rebates accelerate payback. INS-D qualifies for the highest tier of utility rebates — typically $50–$150 per fixture. Combined with 32–58% energy savings, most heavy industrial retrofits achieve payback in 12–18 months.
Case Study
450,000 sq ft Steel Processing Facility — Gary, IN
Replaced 240 × 1000W metal halide fixtures with 240 × INS-D 580W (30° beam, 50ft mounting). Dust-proof IP66 rating eliminated monthly lens cleaning. DLC Premium rebates from NIPSCO covered $100/fixture. CRI improved from 65 to 80, reducing quality inspection defects by 18%. Heat-rated drivers maintained 95% lumen output after 12 months in 60°C ambient.
$185,000
Annual Energy Savings
16 mo
Payback (after DLC rebates)
18%
Fewer Inspection Defects
Ready to upgrade your heavy industrial lighting?
Get a free photometric layout, IES RP-7 compliance review, and energy savings analysis for your steel mill, foundry, or heavy industrial facility.