Metal Box

However, metal enclosures are one of the most significant and popular types of metal items. The sizes of metal enclosures can range from extremely big (as is the case with housing for electrical substation equipment) to extremely small (as can be the case with consumer light switch fixtures).

Metal boxes can be constructed in any suitable shape, including rounded, circular, cylinder, and simple, regular designs like rectangles and squares. These metal enclosures can readily be stamped or pierced with holes to permit the transmission of cords, wires, and cables through the metal, especially in the case of housing electrical equipment.

They can be equipped with thick doors or glass, making it simple to check on the machinery inside the enclosure.

Manufacturing of Metal Boxes

Metal boxes are frequently created using metal stamping methods. These procedures can mold flat sheet metal into straightforward or intricate shapes. Deep-drawn stamping is particularly helpful for enclosures that must be taller than they are wide, like those that shield cylindrical tanks.

Deep-drawn stamping produces smooth, long-lasting enclosures with excellent precision in various applications. In addition, stamping this way can reduce the number of connected edges or material seams on a part with this manufacturing method, which lowers the risk of component failure or the requirement for material reinforcing at weaker seams.

For enclosures with increasingly complex configurations, progressive die stamping, which enables continuous manufacturing with dramatic shaping, is helpful. In addition, the material can be modified incrementally using the progressive die technique to decrease material fatigue and boost the strength of the finished component. This process is additionally useful and well-liked for producing these components when finishing procedures are considered.

Metal enclosures frequently require additional processing to harden and stiffen the case, regardless of the material or manufacturing method. Finishing techniques like annealing, hardening, or another heat treatment can better prepare metal enclosures for the worst environments, such as corrosive or extreme temperature conditions.

Types of Metal Boxes

Some of the types of metal boxes include:

Standard Rectangular Boxes

Standard rectangular boxes, sometimes called "single-gang" or "one-gang" boxes, are frequently employed for single-light fixture switches and outlet receptacles. Outlet receptacles can join some forms to create larger boxes that can house two, three, or more devices side by side. These forms can remove their sides.

2-Gang, 3-Gang, and 4-Gang Metal Boxes

In the same way that regular rectangular boxes contain household switches and outlets, gangable electrical boxes are larger to allow for the side-by-side mounting of two, three, or four devices. Using regular rectangular boxes with gangable designs—which allow the sides to be taken off so the boxes can be connected to form larger boxes—you can achieve the same effect. Although sturdy galvanized steel is the most common material for gangable electrical boxes, several hardware stores also carry snap-together plastic versions (sometimes more costly).

Round Pan Metal Boxes

Round pan, or "pancake," alternatives are shallow circular boxes frequently used for light fixtures mounted on walls or ceilings weighing less than 50 pounds. Only some pan boxes can be used for mounting ceiling fans, but some types of metal pan boxes with detailed ratings may. The fixture wires must be inserted inside the circular pan box and connected correctly. There is barely room for two or three electrical connections in these narrow electrical boxes. You will need a full-sized octagon or circular electrical box with additional volume if more wire connections are needed. The number of cables within should never exceed the electrical box's safe-fill capacity.

Junction Box

A junction box is a word used to designate any common electrical box that covers wire splices rather than a specific box. Other boxes can also be used for this use, but the traditional box for junctions is a 4-inch square box (either metal or sturdy plastic), which provides plenty of area for creating wire connections with several wires or cables. Depending on the junction box type selected, prices will vary.

Advantages of Metal Boxes

Technically, a metal box could be created from any metal or metal alloys like aluminum or cast iron. However, since we are focusing specifically on their function of housing electrical components, we will refer to metal boxes as steel enclosures in this section due to the benefits steel provides for protecting electrical parts.

• Steel enclosures are impervious to corrosion, vermin, and fire. These enclosures can tolerate extreme environmental conditions, like extremely hot and humid regions. Steel can maintain its strength even at high temperatures and is resistant to scaling. Since the electrical components housed within need to be protected from environmental factors, they are equipped with a seal to prevent moisture from getting inside.
• Steel can be recycled numerous times, unlike other metals, making it a more environmentally-friendly material. Steel is lightweight and portable, and it wastes fewer raw materials.
• In the long term, employing a steel enclosure is more cost-effective than using another kind of enclosure. Its initial purchase price may be slightly greater than other options like plastic or ABS (acrylonitrile butadiene styrene). Nevertheless, it will undoubtedly endure a long time and require little upkeep.
• Steel enclosures are fire-resistant since the material is considered to be non-combustible. As a result, there are fewer flammable items inside industrial buildings utilizing these enclosures. One can also purchase Atex-rated enclosures for enhanced security, which can be used in potentially explosive environments like chemical plants.

Applications of Metal Boxes

• A metal electrical enclosure, such as a fuse box, a crucial piece of electrical regulatory equipment that controls power output and prevents electrical fires, is present in every facility that uses electricity. Outdoor electrical meters are also necessary to efficiently operate electrical components in homes and businesses. Both fuse boxes and electrical meters are encased in metal casings that shield them from accidental impact and exposure to impurities like dust and grime.
• Metal boxes are frequently necessary to secure and efficiently operate electrical components in industrial settings. Large amounts of dust and debris are produced by numerous industrial processes, which can hinder the performance of exposed mechanical or electrical components. Metal enclosures offer such protection in a variety of contexts.