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There are many types of pancake junction boxes. The difference lies mainly in the nature of the environment in which the junction box is expected to be used. Below are some of the more commonly used types.
This is the common form of the pancake junction box, which is generally intended for indoor applications. Such a junction box is most often made out of steel or aluminum, thus providing required strength and durability. This type of box may be used in residential or commercial buildings to protect electrical connections.
Weatherproof boxes are specially made for outdoor use or even in areas where moisture and dust are likely to penetrate. Such boxes are made with gaskets and also have tighter lids to enable them to withstand adverse environmental conditions. These types prove especially useful in outside lighting, patio fans, or even in areas where electrical devices are exposed to the elements.
Commercially, electrical junction boxes can be made to contain an atmosphere that may be potentially explosive or contain flammable substances. These are made of strong materials, such as aluminum alloys or stainless steel, and, therefore, can withstand internal overpressure without any failure caused by ignition. These types are more commonly used in the petrochemical industry and in places with hazardous vapors or flammable liquids.
Gang extension junction boxes are simply designed to allow more space for electrical connections and accommodate more circuits. These kinds of boxes are normally employed when running more than one electrical device in close proximity. They may be either pancake style or deep style and are normally made from metal or PVC.
This is the junction box that is designed to facilitate the easy entry of flexible conduits for wiring. These kinds of boxes usually consist of knockouts on the sides that can easily be removed for running constant wiring. Flexible conduits are, in most cases, used in regions where wiring needs to be more tenable because of moving mechanical elements.
Pancake junction boxes are made from different materials. Each has its benefits concerning strength and applicability. Below are some of the common materials used in making pancake junction boxes.
Pancake junction boxes made of steel are very durable and strong. Usually, steel boxes are used for protection against heavy operations as well as for impact resistance. The metal is normally coated with zinc to prevent rusting, hence making it suitable for indoor use.
Over aluminum pancake junction boxes, users enjoy a more lightweight option with excellent corrosion resistance. This makes it suitable for both indoor and outdoor use. aluminum is non-magnetic, thus making the junction boxes ideal for industries that deal with sensitive electronic equipment.
Stainless steel junction boxes are famous because of their resistive qualities against corrosion, weather elements, and also chemical exposure. These are, thus, extremely useful in industries where chemical reactions are frequent, such as in pharmaceutical or petrochemical industries. They have the added advantage of being non-magnetic and extremely durable.
For users who want to avoid the metal's disadvantages, thermoplastic pancake junction boxes are ideal, and users consider these PVC boxes to be great. These are lightweight and corrosion-free and thus suitable for outdoor use, especially where moisture, chemicals, or acidic elements are present. They are non-conductive, which enhances safety features against electrical interference.
Various industries widely use pancake junction boxes to protect electrical connections and ensure system safety and reliability. Below are the commercial applications.
Junction boxes are used in the electrical installation of new buildings and renovation works. They provide the basic support for arrangement and safe accommodation of wiring. These are particularly important in the residential and commercial sectors since reliable and up-to-code wiring has to be ensured.
Petrochemical industries employ pancake electrical boxes manufactured with explosion-proof features as a mandatory safety condition. They ensure the safety of operations by protecting electrical wiring in environments with explosive chemicals, flammable gases, or in adverse working conditions.
In factories and industries with machines, heavy equipment, and other machines, pancake junction boxes are used to manage wiring for an organized system. Manual work boxes keep electrical connections from being jammed, thus enhancing safety and making machine maintenance much easier.
Communication cabling systems also require pancake junction boxes to manage wiring under control, thus preventing interference. These are widely used in data processing, internet provision, and telephone services to ensure connections' stability, especially in high-performance environments.
Going to agriculture, electrical junction boxes are required for the wiring of pancake penile heating systems, irrigation pumps, and all kinds of barns and greenhouses. They have to withstand outdoor elements and ensure reliable operation in conditions required for farming activities.
Last but not least, junction boxes are extensively used in the wiring of traffic lights, subways, and other public transport systems. They are crucial in rail and road transport systems since they protect the wiring from adverse weather elements and promote durability and safety in electrical systems used in transportation.
When purchasing a junction box, there are several factors a buyer has to keep in mind. Below are the main considerations one should make.
A buyer should first consider the material with which the box is made of. Ideally, metal boxes like steel and aluminum are more durable than thermoplastic—which is more lightweight but non-conductive—perhaps offering more resistance to corrosion. Buyers also need to consider whether they will use the junction boxes indoors or outdoors when selecting materials. Whereas steel zinc-coated boxes are ideal for indoor use, weatherproof boxes are suitable for outdoor environments.
This is quite a critical factor. Customers need to select junction boxes in the right sizes corresponding to the wiring in the room. A box that has been sized to accommodate the traffic of electrical wires will avoid overcrowding and, thus, potential overheating. Buyers should also factor in the number of knockouts needed for wiring.
All electrical equipment should meet the National Electric Code requirements (NEC). Buyers should also be on the look for any other safety and performance standards. In some cases, pancake junction boxes used in certain industries may have to meet particular standards.
Weather-resistant gaskets, such as those found in weatherproof pancake junction boxes, are important for outdoor, coastal, or humidity-chamber use. Buyers should ensure the boxes are fitted with protective seals to resist moisture, dust, and any other weather elements as needed in outdoor spaces.
For example, in petrochemical or explosive environments, only explosion-proof boxes will be suitable. Pharmaceutical and food processing industries will most probably require boxes made of stainless steel to avoid rust and easy cleaning. Similarly, telecommunication and data centers will require boxes with low electromagnetic interference, easy access, and good cable management.
Interestingly, both the pancakes and the regular junction boxes serve the same purpose of providing protection for electrical wiring. However, the only difference is their shape and profile. Pancake junction boxes are shallower and flatter, while the others are deeper and more cylindrical. So a pancake junction box is best when there are limited installation spaces.
Yes, electrical junction boxes must be secured in electrical installations, especially in commercial and residential buildings, for safety reasons. They protect the electrical wiring from damage and also prevent accidental contact.
