Custom linear lighting · Continuous runs
Continuous linear runs, planned section by section
A long, seamless line of light is really a set of joined sections, corners, feeds and drivers. Getting the plan right is what makes it look continuous.
Short answer
A continuous linear run is made from factory sections joined end to end, plus corner modules where the run turns. To make it work, plan four things: the section breakdown that adds up to the required length within tolerance, the corners (L, T, X), the power feed points, and the drivers, each sized to the load it carries with headroom. Field-verify critical dimensions before release when the room is not built yet.
Key takeaways
- Total run length = sum of sections + corners + end caps, within the manufacturer’s tolerance.
- Every driver is sized to its connected load with headroom (commonly loaded to about 80%).
- More feeds mean shorter circuits and less voltage drop.
- Wall-to-wall runs need a field dimension check before release.
Anatomy of a continuous run
| Component | Role |
|---|---|
| Sections | Factory lengths joined end to end; may be lit or unlit |
| Joiners / alignment splines | Keep sections straight and light seams minimal |
| Corners (L, T, X) | Turn the run; lit or unlit |
| End caps | Close the run; add a few millimetres at each end |
| Feed kits | Where mains or low-voltage power enters the run |
| Drivers | Integral in the housing or remote, each sized to its load |
| Mounting | Suspension kits, recessed brackets or surface clips at set spacing |
Worked example: section breakdown
Target: a 30 ft 0 in wall-to-wall recessed run, sections available in 1 ft increments up to 8 ft, end caps 0.25 in each.
- Allow for end caps: 30 ft − 0.5 in = 29 ft 11.5 in available for sections.
- Choose sections: 8 + 8 + 8 + 5 = 29 ft.
- Remaining 11.5 in: use a 1 ft filler if the manufacturer offers one that can be ordered short, or adjust the ends with trim.
- Confirm the as-built wall dimension on site before release.
Feeds and drivers
Each driver can power a limited load, and each circuit a limited current. Split long runs into zones and feed each one. The load per zone is:
zone load (W) = lit length (ft) × wattage per foot (W/ft)
Choose a driver whose rated power is comfortably above that load. See how to size an LED driver for the full method, and 24V vs 48V for how voltage affects run length on low-voltage systems.
Related
- Guide · Drivers How to size an LED driver for linear lighting Size an LED driver in three steps. Work out the connected load from length and watts per foot, add headroom so the driver runs at about 80% of its rating, and split long runs into zones. Worked examples for 24V and integral drivers. →
- Guide · Low-voltage systems 24V vs 48V linear lighting 48V linear lighting carries the same power at half the current of 24V, so voltage drop in volts halves and, as a share of supply voltage, falls to a quarter. That means longer runs and fewer feeds. Worked voltage-drop example and when 24V is still the better choice. →
- Custom linear lighting · Suspended Suspended linear lighting Suspended linear LED pendants for offices, classrooms and open ceilings, direct or direct/indirect, in custom run lengths with corners, supplied across Canada with drivers, controls and suspension hardware. →
- Guide · Quoting What information is needed for a custom linear lighting quote The information a supplier needs to quote custom linear lighting accurately, split into must-haves and nice-to-haves, from run lengths and mounting to voltage, dimming and delivery, plus what happens when you only have part of it. →
Frequently asked questions
What is the maximum length of a continuous linear run?
There is no single limit for the run; the limit is per circuit and per feed. Long runs are broken into electrical zones, each fed and driven separately, while the housing stays continuous. The manufacturer’s maximum length per feed sets how many feeds are needed.
How do linear lighting corners work?
Corner modules (L, T or X) join straight sections at an angle. Some are lit to keep the line of light continuous through the corner; others are unlit connectors. The corner’s own dimensions count toward the run length.
What tolerance should I allow for wall-to-wall runs?
Allow for both the building tolerance and the product tolerance per section. Many manufacturers offer a filler or adjustable end section to absorb the difference.
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