RACO Steel Boxes and Covers

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GENERAL INFORMATION – STEEL BOXES AND COVERS

Application: Steel Boxes

RACO® high-quality steel boxes:

• Are used in branch circuit wiring to splice wires
• Accommodate wiring devices, such as switches and receptacles
• Most may also serve as fixture supports
• Provide excellent protection for wiring system or devices
• Must be closed with a cover, light fixture canopy or wall plate
• Permit access to conductors for maintenance
• Allow for branch circuit runs
• Provide two-hour fire rating for 4X4 or smaller wall opening

Product Features: Outlet Boxes for Fixture or Fan Support

These high-quality boxes:

• Are listed to support lighting fixture canopies or fans
• Feature oversized #10 screws to provide strength and rigidity

Product Features:

Patented TKO® Knockouts

• TKO® knockouts offer greater flexibility with RACO® patented combination ½” and ¾” knockout
• Stock just one product instead of two or three
• One product for the installer to carry

TKO® Provides Reliable Grounding Path

• Independent tests conducted by UL prove that the TKO® passes the same high-current fault test used to test grounding bushings and ground lugs
• RACO® TKO® knockout is UL Listed, providing bonding without the use of bonding jumpers
• Suitable for bonding without any additional bonding means around concentric (or eccentric, TKO) knockouts where used in circuits above or below 250V
• This knockout does not impair the electrical connection to ground

Most RACO® Boxes Have At Least One Tapped #10-32 Grounding Hole

• The products that do not have a grounding hole are: plenum boxes catalog numbers 226 and 239

Combination Screw Heads

• Cover and clamp screws have combination slotted/Phillips heads
• Self-tapping screws provide for 100% thread engagement

Metallic Boxes: Fire Resistance Rating Wall Penetrations*

Listed single – and double-gang metallic outlet and switch boxeswith metallic or nonmetallic cover plates, also 4X4 and octagon boxes may be used in bearing and nonbearing wood stud and steel stud walls with ratings not exceeding two hours.

The surface area of individual metallic outlet or switch boxes shall not exceed 16 square inches through a fire rated wall. The aggregate surface area of the boxes shall not exceed 100 square inches per100 square feet. Boxes located on opposite sides of walls or partitions shall be separated by a horizontal distance of 24 inches.

The metallic outlet or switch boxes shall be securely fastened to the studs, and the opening in the wallboard facing shall be cut so that the clearance between the box and the wallboard does not exceed 1/8 inch.

*Reference: UL Fire Resistance Directory (Orange Book)

Standard Material: Steel Covers, Outlet And Switch Boxes

• Steel boxes and covers are made of .0625 inch thick pre-galvanized sheet steel
• Handy Box covers are made of .030 inch thick galvanized sheet steel

Compliances

RACO® steel boxes and covers generally carry the following compliance ratings. Check specific catalog pages for individual compliances.

• UL Listed – Standard 514-A, file E195978 (“QCIT” Category)
• Boxes are listed for their Electrical Applications (electrical codes), UL Green Book
• Boxes are listed for mechanical properties, including the Two-Hour Fire Rating, (building codes) UL Orange Book
• CSA Certified – C22.2 #18, CSA File LR-1082
• U.S. Federal Specification and Standards W-J-800
• ANSI/NEMA OS1
• Federal Manufacturer’s number 28488

Reference Data

• TKO® knockout U.S. Patent 4,640,433; Canada Patent 1,260,597
• Ceiling fan outlet box U.S. Patent 4,892,211; Canada Patent 1,324,360; Mexico Patent 166,125
• Far-side support (#978) U.S. Patent 4,898,357
• BOX-LOC® U.S. Patent 5,408,045 MEXICO Patent 186848
• Adjust-A-Brace® U.S. Patent 5,330,137 and 5,927,667 U.S.
• Steel Stud box Support (#978) 4,898,357 U.S.
• W.P. self tap holes 4,898,453 U.S. and 4,906,206 U.S.

NEMA Member

For installation guidelines and to learn more about RACO products, visit the NEMA website at http://www.nema.org.

The National Electrical Manufacturers Association (NEMA) website is a valuable electrical resource providing the information you need – quickly. Standards and technical information, installation guides, industry news and economic trends, events/meetings, the latest electroindustry, and legislative and regulatory information for more than fifty-one product areas ranging from arc welding to x-ray machines can be found with just a few clicks of your mouse.

NEMA , celebrating its 75th anniversary in 2001, is the leading trade association in the United States representing the interests of electroindustry manufacturers. Founded in 1926 and headquartered near Washington, DC., its 500 member companies manufacture products used in the generation, transmission and distribution, control, and endues of electricity. Annual shipments of these products total $100 billion.

GENERAL INFORMATION – STANDARDS, 1999 NATIONAL ELECTRICAL CODES®

Wiring Capacity: Steel Outlet And Switch Boxes; Cubic Inches

Maximum Number of Conductors or Minimum Size Box Required – National Electrical Code Article 370-16

The purpose of NEC Article 370-16 is to determine the maximum conductor count or the minimum box size required for an application. It also may be used to determine how many other conductors may be added without exceeding the Code-prescribed limit. Most applications have determined the number of conductors. The question that then remains is the smallest (minimum) size box that is permitted. The rules of Article 370-16 are to be used to determine the Code-recognized limit.

Selection of an outlet or junction box for use in an electrical circuit work must take into consideration the maximum number of wires permitted in the box. Safe electrical practice demands that wires not be jammed into boxes because of the possibility of nicks, abrasions or other damage to the insulating material, creating the potential for ground faults or short circuits.

Article 370 – Boxes and Fittings

370-16. Number of Conductors in Outlet, Device, and Junction Boxes, and Conduit Bodies. Boxes shall be of sufficient size to provide free space for all enclosed conductors. In no case shall the volume of the box, as calculated in (a) below, be less than the fill calculation as calculated in (b) below. The minimum volume for conduit bodies shall be as calculated in (c) below.

The provisions of this section shall not apply to terminal housings supplied with motors. See Section 430-12.

Boxes and conduit bodies enclosing conductors, size #4 or larger, shall also comply with the provisions of Section 370-28.

(a) Box Volume Calculations.The volume of a wiring enclosure (box) shall be the total volume of the assembled sections, and, where used, the space provided by plaster rings, domed covers, extension rings, etc., that are marked with their volume in cubic inches or are made from boxes the dimensions of which are listed in Table 370-16(a).

1. Standard Boxes. The volume of standard boxes that are not marked with a cubic inch capacity shall be as given in Table 370-16(a).
2. Other Boxes. Boxes 100 cubic inches (1,640 cu. cm3.) or less, other than those described in Table 370-16(a), and nonmetallic boxes shall be durably and legibly marked by the manufacturer with their cubic inch capacity. Boxes described in Table 370-16(a) that have a larger cubic inch capacity than is designated in the table shall be permitted to have their cubic inch capacity marked as required by this section.

(b) Box Fill Calculations. The volumes in paragraphs (1) through (5) below, as applicable, shall be added together. No allowance shall be required for small fittings such as locknuts and bushings.

1. Conductor Fill. Each conductor that originates outside the box and terminates or is spliced within the box shall be counted once, and each conductor that passes through the box without splice or termination shall be counted once. The conductor fill, in cubic inches, shall be computed using Table 370-16(b). A conductor, no part of which leaves the box, shall not be counted. Exception: Where an equipment grounding conductor or not over four fixture wires smaller than #14, or both, enter a box, from a domed fixture or similar canopy and terminate within that box, it shall be permitted to omit these conductors from the calculations.
2. Clamp Fill. Where one or more internal cable clamps, whether factory or field supplied, are present in the box, a single volume allowance in accordance with Table 370-16(b) shall be made based on the largest conductor present in the box. No allowance shall be required for a cable connector with this clamping mechanism outside the box.
3. Support Fittings Fill. Where one or more fixture studs or hickeys are present in the box, a single volume allowance in accordance with Table 370-16(b) shall be made for each type of fitting based on the largest conductor present in the box.
4. Device or Equipment Fill. For each yoke or strap containing one or more devices or equipment, a double volume allowance in accordance with Table 370-16(b) shall be made for each yoke or strap based on the largest conductor connected to a device(s) or equipment supported by that yoke or strap.
5. Equipment Grounding Conductor Fill. Where one or more equipment grounding conductor(s) enter(s) a box, a single volume allowance in accordance with Table 370-16(b) shall be made based on the largest equipment grounding conductor present in the box. Where an additional set of equipment grounding conductors, as permitted by Section 250-74, Exception #4, is present in the box, an additional volume allowance shall be made based on the largest equipment grounding conductor in the additional set.

Reprinted with permission from the NFPA 70-1999. National Electrical Code®, Copyright© 1999. National Fire Protection Association , Quincy, MA 02269. This reprinted material is not the complete and official position of the NFPA on the reference subject which is represented only by the standard in its entirety. National Electrical Code®, and NEC®, are registered trademarks of the National Fire Protection Association, Quincy, MA.

GENERAL INFORMATION – BOX SELECTION

CONDUIT STEEL BOX SELECTION CHART
CU.IN	42.0	30.3	29.5	21.5	21.0	18.0	16.5
CONDUIT STEEL BOXES
	4-11/16" Sq. 2-1/8" Deep	4" Sq. 2-1/8" Deep	4-11/16" Sq. 1-1/2" Deep	4" Sq. 2-1/8" Deep	4" Sq. 1-1/2" Deep	Switch 3-1/2" Deep	Handy 2-1/8" Deep

CONDUIT STEEL BOX SELECTION CHART
CU.IN	15.5	14.0	13.0	12.5	6.0
CONDUIT STEEL BOXES
	4" Oct. 1-1/2" Deep	Switch 2-3/4" Deep	Handy 1-7/8" Deep	Switch 2-1/2" Deep	4" Rnd. Pan 1/2" Deep

CABLE STEEL BOX SELECTION CHART
CU.IN	30.3	21.5	21.0	18.0	15.8	15.5	14.0	12.5	4.0
CABLE STEEL BOXES
	4" Sq. 2-1/8" Deep	4" Oct. 2-1/8" Deep	4" Sq. 1-1/2" Deep	Switch 3-1/2" Deep	Switch 2-9/64" Deep	4" Oct. 1-1/2" Deep	Switch 2-3/4" Deep	Switch 2-1/2" Deep	3-1/2" Rnd. Pan 1/2" Deep

Calculate The Minimum Size Box

Part (1) of Section 370-16(a) of the National Electrical Code describes the detailed way of counting wires, as well as clamps, fittings or devices (i.e., switches, receptacles, combination devices) – by establishing an equivalent conductor value for each. Those values are added together to get a total number of conductors. The minimum size box is the smallest one in Table 370-16(a) that can accommodate that number of conductors.

1. No matter how many ground wires come into a box, they only count as one conductor within the box.
2. Any wire running unbroken through the box counts as one wire.
3. Each wire coming into a splice device (crimp or twist-on type) is counted as one wire.
4. Each wire coming into the box and connecting to a device counts as one wire of that size.
5. Fixture studs, cable clamps and hickeys are to be counted as one regardless of how many there may be. If a box contains two cable clamps, the total is only to be increased by one.
6. Where devices are mounted in the box, the total conductor count must be increased by two for each mounting strap.

Examples:

1. Conduit Boxes: Supply power to a switch that will control a remote light with #14 conductors. Metal conduit and fittings will be used as the wire way. You must provide space for four conductors and one switch, totaling 6. Read across the line “Deductions” in the Box Fill Table to column 6, the read down to the minimum cubic inches required for #14 conductor. This example requires a minimum of 12.0 cubic inches.
2. Cable Boxes: This example will illustrate how the minimum size is determined for a box with cable clamps fed by two #12-2 nonmetallic sheathed cables and supplying a 15A duplex receptacle. After supplying the receptacle, the conductors are extended to other outlets.
   
   

   Circuit conductors	4
   Ground conductors	1
   Cable clamps	1
   Device (receptacles)	2
   Total	8

   
   Using the Box Fill Table below, read across the line “deductions” to column 8, then down to the minimum cubic inches required for #12 conductor. This example requires a minimum of 18.0 cubic inches.

“A” Bracket: Positions handy box against face and side of stud. Very rigid.	“B” Bracket: Face mounts on front edge of wood stud. Use when space between studs is limited.	“D” Bracket: Allows box to be mounted on either side of stud.	“FA” Bracket: Allows box to be flush mounted to stud or joist.

“FM” Bracket: Mounts on flat side of stud.	“J” Bracket: Spurs, slotted holes for toe-nailing. Gauging notches at 3/8” and ½”.	“LB” Bracket: Face mounts on front edge of wood stud. Use when space between studs is limited. 5/8” offset to clear narrow door molding.	BOX-LOC® “MS” Bracket: Positions box on either side of stud.

“TS” Bracket: Side-mount bracket for octagon, square, switch and handy boxes. Gauging tabs and recessed nailing spur. Very rigid.	“W” Bracket: Positions box away from side of stud to clear the trim molding of a door frame.	“FH” Bracket: Side –mount bracket with hooks that drive into face of stud.

"L" TYPE	"X" TYPE	"#9 OR AOL" TYPE	"BN" TYPE	"Q" TYPE

KNOCKOUTS AND PRIOUTS
½” CONDUIT KO	¾” CONDUIT KO	1” CONDUIT KO	TKO CONDUIT KO	CABLE PRIOUTS Always in pairs.

PLASTER EARS
Adjustable plaster ears are included on many switch boxes and one octagon box. They are set forward 1/32”.
	ONE-SCREW EAR	TWO-SCREW EAR

RACO Nonmetallic Cable Boxes

GENERAL INFORMATION – STANDARDS, 1999 NATIONAL ELECTRICAL CODES®

RACO Floor Boxes

STANDARDS, 1999 NATIONAL ELECTRICAL CODE®

General Applications

RACO floor boxes are ideally suited for heavy floor traffic applications, such as shopping malls, retail stores, banks and schools. Floor boxes are installed in poured concrete floors and are fed with conduit. RACO’s complete line includes both single service and three-service (power and voice/data) floor boxes, which are available in cast iron, stamped steel and PVC plastic. Floor box covers and carpet flanges are offered in brushed brass and textured thermoplastic in two designer colors, ivory and gray. RACO floor boxes:

• Are used in branch circuit wiring
• Accommodate wiring devices such as receptacles for voice/data
• Provide excellent protection for wiring system or devices
• Must be closed with a cover
• Permit access to conductors for maintenance

Non-Adjustable Style Floor Box Features

This type of box has no means for adjustment. It is usually installed in wooden floors or used for retrofit in concrete.

RACO quality non-adjustable floor boxes feature:

• Rugged cast iron for strength and ground continuity
• Factory-installed ground wire
• Simple one-piece floor box design offers flexibility for power outlet or voice/data outlets
• Conveniently positioned conduit entries are tapped and plugged

Fully-Adjustable Floor Box Features

This type of box has leveling screws for height and leveling adjustments to be made before the concrete is poured, and final leveling adjustments after the concrete is poured. The maximum leveling adjustment is a 7° tilt.

Fully-Adjustable Floor Boxes feature:

• Concrete-tight floor boxes for use in power or voice/data
• Cast iron boxes classified as water-tight and concrete-tight, typically used below grade where excessive moisture is present
• Choice of materials – stamped steel or cast iron
• Cast iron floor box including factory-installed ground wire, and multiple gang boxes with one ground wire per gang
• Multiple gang boxes provided with low voltage partitions
• Ample wiring space for any combination of power outlet or voice/data outlets

Standard Materials

• Nonmetallic floor box is made of heavy-duty PVC (Polyvinyl chloride) compound. Base material is recycled
• Steel floor boxes are made of .0625-inch-thick steel
• Cast iron floor boxes are made from cast iron having a high tensile strength
• Solid brass covers and carpet flanges
• Nonmetallic floor box covers and carpet flanges are made of high-strength thermoplastic (ABS)

Standard Finishes

• Natural gray finish on nonmetallic floor box
• Nonmetallic floor box covers and carpet flanges are available in gray and ivory
• Steel boxes have a zinc coating
• Cast iron floor boxes have a gray powder coat paint finish
• Solid brass covers and carpet flanges have a brushed finish

Compliances

Floor boxes are subject to the same code requirements and minimum conductor fill requirements as other boxes. RACO floor boxes carry the following compliances:

• UL Standard 514-A, file E4872
• Boxes are listed for their Electrical Applications (Electrical Codes), UL Green Book
• U.S. Federal Specification and Standards W-C-583B
• Federal Manufacturer’s number 28488

Reference Data

• Minimum wiring capacity calculation can be found on pages A8 of this catalog.

Installing a fully-adjustable floor box in a poured concrete floor: RACO provides with all box assemblies or flanges a metallic concrete cover. The concrete cover permits pouring concrete to the top of the box. The cover is then easily removed after the pour. To install a box:

1. Locate box and install conduit in accordance with local codes
2. Secure box to reinforcing bar (mesh)
3. Make pre-pour height and leveling adjustments
4. Grease inside of cement cover and install on box
5. Grease outside of cement cover
6. Apply bead of grease on exposed portion of adjusting collar
7. Tape cement cover to box
8. Pour concrete
9. After the concrete has set, remove the concrete cover
10. Pull wires and install wiring device
11. Make final pour adjustments, and grout around the box if required
12. Install cover plates and/or accessories

Links to More Information

• Non - Adjustable Floor Box System
• Fully - Adjustable Floor Box System
• PVC Floor Box System

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