Retrofit vs Dedicated: The Decision That Drives the Labor Bill
A buyer once asked us whether to relamp 600 fluorescent troffers with T8 retrofit tubes or rip them out for dedicated LED battens. The answer hinged on one number he had not checked: how many of those old ballasts were already failing.
Retrofit lamps reuse the housing and cut install labor roughly in half, but they inherit every problem in that housing. If the sockets are corroded and the ballasts are dying, ballast-bypass rewiring eats the labor savings and you are halfway to a new fixture anyway. Dedicated battens cost more up front but give you a clean driver, integrated controls, and a warranty that covers the whole luminaire, not just the tube.
The rule we give: intact housings and sound sockets, retrofit is defensible. Anything else, and especially new construction, buy the dedicated batten.
Efficacy by Space: The Number Suppliers Hope You Will Not Normalize
Efficacy is lumens per watt, and the single most abused number on a linear-fixture spec sheet. Suppliers quote board efficacy, chip efficacy, or system efficacy depending on which looks best. You want system efficacy: fixture lumens divided by fixture watts. The gap between chip and system is 15-30%.
Efficacy Targets by Space
| Space | System Efficacy | What the Number Means |
|---|---|---|
| Office / school | 120-140 lm/W | Mainstream 4000K linear quality band |
| Warehouse / industrial | 150-170 lm/W | Long hours, efficacy is the whole story |
| Retail / corridor | 110-130 lm/W | Glare and appearance matter more |
| Below 110 lm/W | Last-generation | Walk away for new projects |
A supplier quoting 160 lm/W on a board but 125 lm/W as a system is not lying. They are quoting the wrong number for a buying decision. Ask for the LM-79 report and read the system figure.
Diffusers: Prismatic, Opal, or Micro-Prismatic
The diffuser decides whether the people under the fixture are comfortable or squinting. Prismatic diffusers direct light downward and control glare, the right choice for offices, schools, and anywhere people sit under the light for hours. Opal diffusers spread light evenly and hide the LED dots, the right choice for retail and corridors where the fixture is visible and needs to look clean.
Micro-prismatic sits between them: high output with strong glare control, the standard for UGR-limited office fit-outs. Get the diffuser wrong and you get glare complaints in the office or dim, muddy light on the sales floor.
CCT by Application
4000K is the neutral default for offices and task work; 3000-3500K warms up retail and hospitality; 5000K and above belongs in warehouses and exterior bays where color temperature is about perceived brightness, not comfort. Keep the CCT tolerance to ±150K so a long run of fixtures does not drift warm-to-cool along the ceiling.
Emergency Backup and Sensors
If the space is a means of egress or a power failure strands people in the dark, emergency lighting is not optional. Most codes demand 90 minutes of runtime at a defined illumination level. For anything under a few hundred fixtures, integrated emergency packs with battery, inverter, and test switch are simpler than a central system.
Check the battery chemistry. LiFePO4 outlasts NiCd and does not have the memory effect. Confirm the self-test interval and the replacement cycle in the spec, because a fixture whose battery died three years ago is a compliance gap nobody notices until the power fails. Occupancy and daylight sensors built into the batten are the difference between a 60% energy saving and a 40% one.
The Pre-Order Verification Sequence
Before the Bulk Order
Common Questions from Buyers
T8 retrofit lamps vs dedicated LED battens — which should I buy?
What luminous efficacy should I demand for an office versus a warehouse?
Prismatic or opal diffuser — which one for which space?
Do I need emergency battery backup in linear fixtures, and what runtime?
How do I verify lumen output and driver quality on linear fixtures?
Find verified linear and batten fixture suppliers with LM-79 reports on Compare2Best.