Introduction to Ceiling and Wall Electrical Boxes

Lighting, Ceiling Fan and Junction Boxes

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Electrical boxes are a critically important component of your home's electrical system. However the variety of boxes can seem confusing when you're planning your project. So this tutorial will describe the different types of electrical boxes you find in the ceiling and wall for lighting, ceiling fans and junction boxes. There are varieties for plastic and metal boxes, new work and old work boxes, round, square and octagonal boxes. And they come in depths ranging from 1/2" to over 3" deep. Then there are boxes with no backs that serve as depth extenders and covers with cutouts for various uses! Well, after reading this tutorial you will understand why there are different box types and in what applications they may be used. Electrical wall and ceiling boxes can be used in many ways, such as:

Join or splice wires together in circuits Mount and house connections for a lamp fixture to a wall or ceiling Mount and house connections for a ceiling fan (when rated for this use and appropriately braced or mounted) Mount recessed in a wall or ceiling or surface mounted Wired using non-metallic electrical cable or metallic conduit and wire applications.

Let's take a look now at the various types of electrical boxes and their features and uses.

Metal and Plastic Electrical Boxes

Example of Metal and Plastic Electrical Box

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Throughout this tutorial you will see examples of metal boxes and plastic boxes. If you are using metal conduit to run wiring to the electrical box, then a metal box is required because the conduit and metal box system itself may be used to ground the system. If you are using non-metallic wiring Type NM-B (nonmetallic-sheathed cable) which is typically found in residential applications as branch circuits for outlets, switches, lighting and so on, then you can use either plastic boxes or metal boxes as long as the cable is secured to the box. With NM-B, grounding occurs with a dedicated wire made part of the cable. Type NM-B electrical cable is the most common way to wire a home and you may hear it referred to generically as Romex. However Romex is a brand name of Southwire Co. for NM cable just as Kleenex is often used to describe facial tissue. Metal boxes come in types known as:

Drawn Steel (1 piece construction); Interlocked / Gangable (typically for switch and outlet boxes).

Plastic boxes can be made from different types of molded plastic and are always 1 piece construction. They can be made from:

PVC (most common); Phenolic Resin; Fiberglass.

Now let's take a look at the various types of ceiling and wall electrical boxes you find in the home.

Round Pan Electrical Box

1/2" Deep Round Pan Box

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ROUND PAN ELECTRICAL BOX Typical Size: 1/2" and 3/4" Deep; 3-1/2" Round Usage:

Metal box typically used for installation of ceiling or wall mounted light fixtures up to 50 pounds. Plastic box may used for outlet mounting. Some types of specially rated metal pan boxes may be used for mounting ceiling fans but not all pan boxes may be used for this purpose. (See Ceiling Fan Rated Boxes section)

Octagon and Round Electrical Box

Octagonal and Round Electrical Boxes

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OCTAGON AND ROUND ELECTRICAL BOX Typical Size: 1-1/2" to 2-1/8 Deep Usage:

Typically used for installation of ceiling or wall mounted light fixtures up to 50 pounds; May be used as a Junction box; Metal box may also be used as a switch or outlet box in surface mounted installations using metal conduit; Round plastic box usually has "ears" for fastening to wall or ceiling in existing or "old work" applications.

Ceiling Fan Rated Electrical Box

Ceiling Fan Boxes Require Special Rating and Design

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CEILING FAN RATED ELECTRICAL BOX Typical Size: 1/2" to 2-1/8 Deep Usage:

Must be rated for ceiling fan mounting by UL in a UL-listed electrical box marked For Use With Ceiling Fans. May be a round or octagon shaped UL Listed box; Requires special fastening due to dynamic loading of rotating fan; Depending on assembly, may accommodate installation of ceiling fan and light fixture up to 75 pounds or more; May be mounted directly (with 4 screws) to ceiling joist, wood blocking or may attach to adjustable brace spanning between ceiling joists.

Application: For a great overview of installing a ceiling fan see this article called Remote Controlled Ceiling Fans. written by Elizabeth Weintraub, About.com's Guide to Home Buying/Selling.

4" Square Box

Square Boxes Provide Maximum Volume for Multiple Conductors and Connectors
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4" SQUARE BOX Typical Size: 1-1/4"- 2-1/8" Deep Usage:

Square boxes provide maximum volume for multiple conductors and connectors; Most often square boxes are used to run multiple conductors in two or more directions to bring power to various electrical devices. (See Junction Boxes); Square boxes may also be installed in ceilings or walls for lighting fixtures, switches or receptacles.

Square, Octagon and Round Box Covers

Different Covers Provide Multiple Use Opportunities

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SQUARE, OCTAGON AND ROUND BOX COVERS Usage:

Covers are used to close an outlet box and are required by code. Never leave a box uncovered. Switches or receptacles may be installed into square or octagon boxes by using covers with cutouts; Octagon or round covers are used for mounting light fixtures; Raised 4 square covers are used for mounting switches or receptacles; Flat round closure plates (5) are designed for use in dry locations to close unused ceiling outlets.

Junction Box

Junction Boxes are Typically Square Boxes

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JUNCTION BOX Typical Size: 4" Square; 1-1/4"- 2-1/8" Deep Usage:

A junction box is an electrical box used to run multiple conductors in two or more directions to bring power to various electrical devices. Junction boxes are required to be installed so they are always accessible; Never install a junction box in a concealed wall or ceiling space where is can not be accessed in the future. Wire connectors (wire nuts) and wire lengths take up a lot of space in a box. Because square boxes provide maximum volume for multiple conductors and connectors they are most often used as a junction box.

Box Extenders: Adding Capacity

Box Extenders Add Wiring Capacity to a Box

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BOX EXTENDERS: ADDING CAPACITY Usage:

Extension rings or box extenders are those funny looking square or octagonal boxes that have no back on them. Extenders are designed to bolt onto the base electrical box and provide additional cubic inch box capacity for wiring and connectors.

Advantages and Disadvantages of Plastic Electrical Boxes

Plastic junction boxes have their advantages and disadvantages. Although they are easy to install, they are not always the best choice for every application. Advantages In electrical installations, electrical boxes are used to install electrical devices, make splices and install light fixtures. This leads to a choice of types of boxes, plastic or metal boxes. Plastic boxes are nonconductive and easy enough to install. They have two nails, both on one side of the box, that allow the box to be fastened to the studs in your home. Plastic boxes have markings on the side that show different depths that the box can be set out to allow flush alignment with the outer wall of drywall or wall surface. This allows the outlet, switch, or light fixture to sit flush against the box opening and the wall face for proper alignment and installation. Disadvantages Plastic boxes have their disadvantages also. Along with the box being plastic, the nail brackets are also plastic. They are easily broken off when installing a box or when you

have to take a box off and reinstall one. Once this bracket clip is damaged or broken off, your mounting options are all but gone. One look at the face opening of the box and youll notice there are two screw holes that make it possible to install a switch, outlet, or other device to the box. As with anything plastic, the threads inside the mounting holes are threaded and they are easily stripped if the screws are not installed properly. Quite often, you may be tempted to put any old screw into these holes, but the threads are usually set to a 6-32 thread. In the event the threads do become stripped, you may be able to still use the box by installing a short drywall screw into the hole, that is, if it isnt cracked or damaged. We want the screw to firmly hold the device in place so that it doesnt short out. As for mounting light fixtures and ceiling fans, I recommend using metal boxes. Although there are some plastic boxes that are designed to support these fixtures, I personally have little faith in the plastic threads that support a fixture over my head. And while we are discussing that matter, keep in mind to use the specially designed light fixture and fan mounting boxes that come complete with mounting brackets. These setups are specifically designed to handle the weight that some of these lights and fans have.

Plastic Electrical Box Uses

What Are Plastic Electrical Boxes?

Plastic electrical boxes have their pluses and minuses. Because they are plastic, there is no need to attach a ground wire to it. Since it is made of a non-conductive material, switches and outlets cannot short out if they touch the side of the box. Plastic boxes usually come with tapped screw holes for easy attachment of switches and outlets. These boxes come in a single-gang, double-gang, and even multiple-gang configurations. You can choose between plastic boxes with nail-on brackets, complete with nails, or a cutin version that has tabs that spin out when tightened to hold the box securely to the wall. The disadvantages of plastic boxes are their brittleness and wire support brackets. Let me explain. If you look at the box, you'll notice that the device screw holes are also plastic. If the screw is lined up when installing the device, you're fine. But get the screw crossthreaded and you have a problem. Suddenly the screw won't tighten down and the device is flopping in the wind. If the metal hole in a metal box strips out, you can just tap it out and it's as good as new. Not so easy with a plastic box.

The same holds true for the nail-on mounting brackets. If you hammer the nails carefully and don't accidentally hit the plastic bracket, you're fine. But slightest miscue of the hammer head on the plastic bracket or body and the box is toast. Metal boxes can pounding and still function.

the take a

The plastic boxes sometimes have plastic push-in tabs to hold the nonmetallic sheathed (NM) wire. These tabs serve their purpose I suppose, but I'd much rather have a wire connector or a metal clamp with a screw that I can tighten the tension to hold the wires in place. In this case however, this box has knockouts to remove with no fastener for the wires. One more thing I'll say about plastic boxes is that if you have a choice between a plastic or metal box, I would definitely choose the metal box every time. Yes, I suppose the plastic boxes are cheaper and easier to put up, but after years of experience, I'd still choose quality over price. My metal box will survive a fire, will your plastic box?