A Complete Guide to Retrofitting Metal Halide With LEDs

Wondering how to upgrade your facility from outdated metal halide lights to efficient, modern LEDs? You’re in the right place. This complete guide to retrofitting metal halide with LEDs is specifically for contractors and facility managers who want to improve workspace lighting, reduce maintenance headaches, and save on energy bills.

We’ll walk you through every step—from understanding how your current metal halide lamps work to installing an LED retrofit. By the end, you’ll know how to make the best retrofit choices and avoid common mistakes.

Understanding Metal Halide Lighting

How Metal Halide Lamps Work

Metal halide lamps use a combination of mercury vapor and metal halide salts to generate bright, white light. When you flip the switch, electricity passes through a gas-filled arc tube, activating those salts, which produce illumination. The lamps rely on ballasts to regulate current and voltage, ensuring the lamp operates smoothly.

Where You’ll Find Metal Halide Lights

• Warehouses and distribution centers
• Large retail stores
• Gymnasiums and sports arenas
• Parking lots and exterior floodlighting

Drawbacks of Metal Halide Lighting

Problems with metal halide lighting have made modern lighting solutions a better alternative in the following ways:

• Metal halide lamps consume large amounts of energy, which pushes up operating costs.
• Metal halide lamps don’t age gradually; their light output diminishes suddenly before total failure.
• Metal halide lamps take several minutes to reach full brightness, making them impractical for spaces that need instant illumination.
• Expect to replace bulbs often compared to modern alternatives.

Why Switch to LED?

LED lights are taking over the commercial lighting market, and for good reasons.

Energy Efficiency and Lifespan

LEDs convert a much higher percentage of energy into light rather than heat. That efficiency means significantly lower electricity bills and less impact on your HVAC systems. Where metal halide lamps typically last around 10,000–20,000 hours, LEDs can run for 50,000. That’s fewer replacements and less downtime for maintenance teams.

Comparing Costs, Performance, and Impact

• Cost: While the upfront cost of LEDs can be higher, energy and replacement savings deliver strong ROI within the first few years.
• Performance: LEDs provide instant-on light, better color rendering, and little to no flicker. They also maintain brightness much longer, reducing dimming over time.
• Environmental impact: Lower energy use and longer life mean less waste and a smaller carbon footprint. Also, LEDs don’t contain mercury.

Considerations Before Retrofitting

Consider these key factors to ensure success before you start your retrofit project.

Check Compatibility

Don’t select retrofit lamps based on wattage alone. LEDs achieve higher brightness (lumens) with much less energy. Always focus on lumen output first to match or exceed your existing metal halide performance.

Understand Voltage Requirements

Most LEDs work with standard voltages from 100–277V. Some commercial spaces use high voltage (277–480V circuits), so always confirm the incoming voltage and select LED ratings accordingly.

Evaluate Lighting Control Systems

Most LEDs work with modern lighting controls, such as dimming, but compatibility can vary among LED models. Make sure your LED retrofit solution works with these features if your facility uses dimming, motion sensors, or smart controls.

Rebates and Incentives

Many utility companies and state programs offer rebates to offset upfront retrofit costs. Check what’s available in your region. These rebates can significantly improve your project’s ROI and help justify the investment to stakeholders.

4 Types of LED Retrofit Options

Choosing the right retrofit type depends on your goals, current fixtures, and how much you want to invest. Here’s what you need to know about the most common options.

1. Ballast Compatible (Plug and Play) LED Bulbs

Upgrade your existing fixture in minutes by removing the old metal halide lamp and dropping in a compatible LED bulb. The LED operates with the fixture’s existing ballast.

Pros:

• Quickest and easiest option.
• No need for electrical rewiring.
• Minimal downtime.

Cons:

• Limited to LEDs that are compatible with the ballast (compatibility is critical for safety).
• Slightly less efficient because the ballast still consumes some power.
• You must replace failed ballasts or upgrade to another retrofit option.

Best for: Quick upgrades when you need a fast solution and can tolerate occasional maintenance.

Step-by-Step Guide:

1. Switch off power to the fixture.
2. Remove the old metal halide lamp.
3. Check your new LED bulb to ensure it’s compatible with your ballast type (refer to the manufacturer’s specs).
4. Install the LED lamp in place of the metal halide lamp.
5. Switch on the power and confirm proper operation.

2. Ballast Bypass (Direct Wire) Corn Bulbs

This option removes the ballast entirely. The new LED corn bulb draws power directly from the main supply, increasing efficiency and removing a common failure point.

Pros:

• More efficient as you eliminate the ballast’s energy use.
• Works with a wide voltage range.
• No more ballast failures.

Cons:

• Requires more work (rewiring the fixture).
• Slightly more permanent installation.

Best for: Long-term retrofits where you want minimal future maintenance and maximum savings.

Step-by-Step Guide:

1. Turn off electrical power and lock out the circuit.
2. Remove the metal halide lamp and the existing ballast.
3. Rewire the fixture so power flows directly to the lamp holder.
4. Install the correct wattage and base corn bulb LED.
5. Restore power and check functionality.

3. LED Retrofit Kits

Retrofitting with an LED kit requires you to remove the inside of the old metal halide fixture and install a new LED module and driver. Kits maintain the fixture’s look but bring it up to LED standards.

Pros:

• Keeps existing fixture housing (great for aesthetic or custom fixtures).
• Offers high efficiency and improved optics.
• All-new internal components reduce future maintenance.

Cons:

• Installation is more complex.
• May require professional help for proper mounting and wiring.

Best for: Spaces where aesthetics or fixture compatibility matter, such as gymnasiums or architecturally sensitive locations.

Step-by-Step Guide:

1. Power off the fixture and remove the metal halide lamp, reflector, and ballast.
2. Install the new LED module in place, attaching it to the fixture’s mounting bracket.
3. Wire the new LED driver according to the kit’s instructions.
4. Secure all components and restore power to test operation.

4. Replace Metal Halide Fixture With an LED High Bay

Sometimes, the best solution is a complete upgrade. Commercial high bay LED lights are ideal for facilities seeking the longest lifespan and highest efficiency.

Pros:

• Maximum energy savings and performance.
• Modern design and improved light distribution.
• Great if your current fixtures are outdated or damaged.

Cons:

• Highest upfront cost.
• Requires new fixture installation.

Best for: New builds, spaces with failing metal halide fixtures, or facility-wide upgrades.

Step-by-Step Guide:

1. Remove the old metal halide fixture.
2. Ensure the mounting point and power connections are safe and appropriate for the new LED high bay.
3. Install the new LED fixture (following manufacturer’s guidance on wiring and mount position).
4. Re-energize the circuit and verify light output.

Getting Started With Your Retrofit Project

This complete guide to retrofitting metal halide with LEDs gives you everything you need to upgrade your facility’s lighting safely and with confidence. Moving to LEDs cuts energy costs and reduces maintenance. Reach out to us at Eco LED Mart today for more guidance on LED product selection!