Chloe Zhang
Electrical boxes are typically made from either metal or plastic. Metal boxes are usually constructed from steel, aluminium, or cast iron, while plastic boxes are often made from PVC or fibreglass. Metal boxes have traditionally been the industry standard due to their strength, durability, and fire resistance, but plastic boxes have become increasingly popular, especially for residential use. Plastic boxes are lightweight, affordable, and easier to install, but they are also more prone to cracking or melting under stress. The choice between metal and plastic boxes depends on factors such as wiring type, installation environment, ease of use, budget, and local building codes.
| Characteristics | Values |
|---|---|
| Material | Plastic (PVC) |
| Conductivity | Non-conductive |
| Installation | Easy to install |
| Cost | Less expensive than metal boxes |
| Safety | Reduces risk of electrical shock |
| Compatibility | Compatible with non-metallic cable wiring |
| Usage | Residential wiring projects, indoor and outdoor use |
| Compliance | Must comply with National Electrical Code (NEC) and local building codes |
| Weight | Lightweight |
| Fireproof | No |
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What You'll Learn
Plastic vs metal boxes
When it comes to electrical boxes, you have two main options: plastic or metal. Each has its own advantages and disadvantages, and the choice depends on factors such as the type of wiring, installation environment, ease of use, and cost.
Plastic Electrical Boxes
Plastic electrical boxes, typically made from PVC, have become a popular choice, especially for residential wiring. They are lightweight, affordable, and easy to install. Plastic boxes are also safer to work with due to their lack of sharp edges and non-conductive properties. Additionally, they do not rust or require an EGC (equipment ground wire). However, one drawback of plastic boxes is their tendency to distort or crack under stress, and the clamps that come with them can make it difficult to remove cables.
Metal Electrical Boxes
Metal electrical boxes, on the other hand, are known for their strength, durability, and fire resistance. Made from steel or aluminum, they are virtually impossible to bend, warp, or crush. Metal boxes are often recommended for commercial projects and are suitable for residential use in certain situations, such as installing ceiling fans or large light fixtures. They are also necessary when using metal-sheathed cables or metal conduit to complete grounding. However, metal boxes can be more challenging to install, especially for DIYers, due to their sharp edges and the need for supplementary clamps. They also tend to be more expensive than plastic boxes.
In summary, both plastic and metal electrical boxes have their pros and cons. Plastic boxes are ideal for those seeking an affordable, lightweight, and easy-to-install option, while metal boxes offer superior strength, durability, and fire resistance. The choice between the two ultimately depends on the specific requirements of the project and personal preference.
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Plastic boxes for residential wiring
Plastic boxes are the most popular choice for residential wiring projects. They are lightweight, easy to install, and less expensive than metal boxes. Plastic boxes are also non-conductive, reducing the risk of electrical shock, and they are compatible with non-metallic cable wiring. Plastic electrical boxes can be placed behind drywall and are usually made from high-impact PVC.
Plastic electrical boxes have become increasingly popular, especially for residential wiring. They are typically made from PVC and offer quick installation, making them good for most residential applications. Plastic new work boxes are commonly used with non-metallic cable wiring and are often used in new construction or when walls are opened up for renovations.
Plastic junction boxes are also available, which enclose wire connections and help protect against short circuits, which can cause fires. These boxes are made from durable, high-grade plastics and are increasingly popular for both indoor and outdoor use. Junction boxes are not a special type of box but any standard electrical box used to enclose wire splices. The most commonly used box for junctions is a 4-inch square box that offers ample space for making wire connections with multiple wires or cables.
Plastic old work boxes are also available, which are designed to be installed in finished walls and allow you to add new electrical devices without affecting your drywall. These boxes have tabs or clamps that grip the drywall from behind. It is important to note that the National Electrical Code (NEC) and local building codes regulate the types of electrical boxes allowed in certain applications, as well as how they are installed.
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Metal boxes for metal-clad cables
Metal-clad cables are commonly used in junction boxes to protect electrical wiring from short circuits, which can cause fires. They are typically made of aluminum, steel, or cast iron, and are strong, fireproof, and incapable of melting. Metal boxes are often stronger than the materials built around them, and some have pre-attached clamps for gripping electrical cables.
Metal-clad cables are used to ground and secure metal conduits or armored cables to boxes and enclosures. They are designed to be used with metal boxes and cannot be connected to plastic boxes unless the plastic box has a bonding strap connecting all of the factory knockouts. This type of plastic box is rare and likely more expensive than a metal box.
If you are running metal conduit through a surface-mount installation, a metal enclosure is the standard choice. Metal boxes are required if the electrical system needs grounding through metal conduits.
When working with metal-clad cables, it is important to ensure that the metal box has knockout holes in the correct locations. Screws should be used in addition to the spurs on the bracket to hold the box in place securely.
Some manufacturers supply anti-short bushings with the cable, or these can be purchased separately. It is also important to note that every metal box needs to be grounded.
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Plastic junction boxes
Electrical boxes, also known as junction boxes, enclose wire connections and protect against short circuits, which can cause fires. They come in metallic or non-metallic materials, with metal boxes usually made from aluminium, steel, or cast iron, and non-metallic boxes made from PVC or plastic.
However, plastic junction boxes are not suitable for all applications. They cannot be used with metal conduit, which is required for some electrical installations, and they may not offer the same level of resilience as stainless steel enclosures. There can also be variance in quality and durability between different plastic boxes.
The choice between plastic and metal junction boxes may be dictated by the National Electrical Code (NEC) and local building codes, which regulate the types of electrical boxes allowed in certain applications.
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Installation and cost
Electrical boxes are constructed of metallic or non-metallic materials. Metal boxes are usually made of aluminium, steel, or cast iron, whereas non-metallic boxes are made of PVC or plastic. Plastic electrical boxes are inexpensive and easy to install, and they can be placed behind drywall. Plastic junction boxes for indoor wiring cost 50% to 80% less than metal boxes but are not as durable. Junction box installation costs $100 to $300 for parts and labour, depending on the installation location, accessibility, and the electrical box size, material, and indoor or outdoor rating. Plastic junction boxes are non-conductive and do not require grounding. However, if the electrical system requires grounding, a metal enclosure is necessary.
The cost to replace an electrical box generally varies between $300 and $1,500, influenced by the type and size of the box, local labour rates, and any required upgrades to wiring or circuit breakers. Installation expenses for a power panel typically range from $1,000 to $3,000, depending on the complexity of the job. Homeowners should be vigilant for warning signs that may indicate the need for immediate replacement to maintain safety and functionality. Starting in 2024, revised regulations and safety criteria are being enforced to improve the safety of power installations, making it crucial for homeowners to ensure their systems meet current guidelines.
Electricians typically charge less per box when installing multiple junction boxes as part of a larger electrical project. For example, light switch installation costs $100 to $300, while replacing an existing light switch costs $50 to $250. Ceiling fan installation costs $150 to $350, including the fan and labour. Junction box prices are $10 to $450 for the part alone, depending on the size, material, and whether the box is weatherproof.
It is important to note that most local building codes mandate a permit for electrical box replacement to ensure that the installation adheres to safety standards and regulations. Additional expenses may be incurred for permits or inspections, which can differ between municipalities. Furthermore, costs for testing and remediating hazardous materials such as asbestos, lead, or radon may apply.
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Frequently asked questions
Electric boxes are typically made of metal or plastic. Metal boxes are usually made of steel, aluminium, or cast iron, while plastic boxes are usually made of PVC or fibreglass.
Plastic electric boxes are lightweight, affordable, and easier to install than metal boxes. They are also non-conductive, so they do not require grounding. Plastic boxes are also less prone to corrosion and rust, making them ideal for areas with moisture.
Plastic electric boxes can distort or crack under stress, and PVC can melt due to overheating. The nail brackets on plastic boxes can also easily break off during installation or replacement.
Metal electric boxes are strong, fireproof, and cannot melt, warp, twist, or crush. They offer a high level of security for electrical wiring applications and provide grounding through their metal structure. However, metal boxes can be more difficult to work with, especially for DIYers, as they have sharp edges and require additional clamps. They are also typically more expensive than plastic boxes.
