Wall Pack Lights: Gasketed vs Non-Gasketed
Wall pack lights are a staple in commercial and industrial exterior lighting, providing essential security and visibility for building perimeters, loading docks, and walkways［1］. When selecting the appropriate fixture for an outdoor environment, one of the most critical technical distinctions is the ingress protection (IP) rating, which is largely determined by the presence of gaskets［2］. The choice between gasketed and non-gasketed wall packs dictates the fixture's ability to withstand moisture, dust, and extreme temperature fluctuations.
This article explores the technical differences, applications, and performance metrics of gasketed versus non-gasketed wall pack lights to assist facility managers and lighting specifiers in making informed decisions.
Comparison Overview
The fundamental difference lies in the sealing mechanism. A gasketed fixture utilizes a compressible material (typically silicone or rubber) between the lens and the housing to create a watertight seal. A non-gasketed fixture relies on tight mechanical tolerances or overlapping geometry to repel water, but does not offer a hermetic seal［3］.
| Feature | Gasketed Wall Pack | Non-Gasketed Wall Pack |
|---|---|---|
| Primary Seal | Silicone/Rubber Gasket | Mechanical Fit / Overlap |
| Ingress Protection | High (IP65, IP66, IP67)［4］ | Low to Moderate (IP40 - IP54)［5］ |
| Water Resistance | Waterproof / Submersible | Splash Resistant / Damp Rated |
| Condensation Risk | Low (Sealed environment) | Moderate (Breathable) |
| Ideal Environment | Heavy rain, snow, coastal areas | Covered walkways, eaves, dry climates |
| Cost | Higher | Lower |
️ Gasketed Wall Pack Lights
Gasketed wall packs are engineered for maximum durability against environmental elements. The "gasket" is typically an O-ring or a formed-in-place gasket made of high-durability silicone or EPDM rubber.
1. Ingress Protection (IP) Ratings
Gasketed fixtures almost always carry a high IP rating, such as IP65 or IP66.
- IP65: Dust tight and protected against water jets from a nozzle.
- IP66: Dust tight and protected against powerful water jets and heavy seas［4］.
This rating ensures that the internal LED driver and chips are completely isolated from external moisture.
2. Thermal Management and Condensation
A common concern with gasketed fixtures is heat buildup. However, modern gasketed LED wall packs often feature breather valves (pressure equalization vents). These vents allow air exchange to equalize pressure without allowing water ingress, significantly reducing the risk of condensation forming inside the lens［6］.
3. Applications
Due to their robust sealing, gasketed wall packs are the standard for:
- Loading Docks: Areas exposed to direct hosing or heavy rain.
- Coastal Areas: Where salt spray can corrode internal components if the seal is breached.
- Cold Climates: Preventing snow melt from seeping into the fixture and freezing, which can crack the housing［7］.
️ Non-Gasketed Wall Pack Lights
Non-gasketed wall packs, sometimes referred to as "ungasketed" or "standard" wall packs, utilize a design where the lens sits flush against the housing or overlaps it without a compressible seal.
1. Protection Levels
These fixtures typically hold an IP54 or lower rating.
- IP54: Protected against dust (limited ingress) and water splashes from any direction［5］.
While they can handle light rain, they are not designed to withstand high-pressure water jets or driving storms.
2. Thermal Efficiency
Because they are not hermetically sealed, non-gasketed fixtures often rely on passive cooling through the housing and natural air convection. This can sometimes lead to better heat dissipation for the LED array itself, provided the ambient temperature is not extreme. However, they are more susceptible to dust accumulation on the internal reflectors over time［8］.
3. Applications
Non-gasketed lights are cost-effective solutions for "damp rated" locations:
- Under Canopies: Gas stations or building overhangs where direct rain is blocked.
- Covered Walkways: Areas protected by roof overhangs.
- Dry Climates: Regions with minimal rainfall or humidity.
️ Technical Analysis: Why the Seal Matters
Moisture and Corrosion
The primary failure mode for outdoor LED fixtures is not the LED chip burning out, but the driver failing due to moisture ingress. In non-gasketed fixtures, humidity can enter the housing during temperature drops (the "breathing" effect). Over time, this leads to corrosion of the electrical contacts［9］. Gasketed fixtures eliminate this pathway.
Maintenance and Cleaning
Gasketed fixtures are easier to clean in dirty environments. Because the seal is tight, facility managers can pressure wash the exterior of the fixture to remove grime, bugs, and dirt without fear of damaging the internals. Non-gasketed fixtures require gentle cleaning to avoid forcing water behind the lens［10］.
LM-80 and TM-21 Ratings
Regardless of gasketing, the longevity of the LED source is measured by LM-80 testing. However, the system longevity is often shorter for non-gasketed units in harsh environments. A gasketed fixture is more likely to achieve its rated lifespan (e.g., L70 > 100,000 hours) in an exterior application because the environment is controlled［11］.
Summary and Selection Guide
When choosing between gasketed and non-gasketed wall packs, the decision should be driven by the specific environmental exposure of the installation site.
Rule of Thumb: If the fixture will be directly exposed to rain, snow, or high humidity, a Gasketed (IP65+) fixture is mandatory. If the fixture is installed under an overhang or eave, a Non-Gasketed (IP54) fixture is a sufficient and cost-saving alternative.
| Decision Factor | Choose Gasketed If... | Choose Non-Gasketed If... |
|---|---|---|
| Location | Open wall, facing weather | Under an overhang or roof |
| Climate | Heavy rain, snow, or coastal salt air | Arid or mild climates |
| Cleaning | Needs pressure washing | Standard dusting/wiping |
| Budget | Long-term durability is priority | Initial cost reduction is priority |
References
- IES Lighting Handbook - Commercial Exterior Lighting Guidelines - Illuminating Engineering Society
- Energy Star - Solid-State Lighting Product Specifications - Energy Star.gov
- DLC (DesignLights Consortium) - Technical Requirements for Exterior Luminaires - DesignLights.org
- IEC 60529 - Degrees of protection provided by enclosures (IP Code) - International Electrotechnical Commission
- NEMA WD-6 - Enclosure Types for Electrical Equipment - NEMA.org
- LED Professional - Thermal Management and Breather Valves in LED Luminaires - LED-professional.com
- DOE Solid-State Lighting Program - Outdoor Lighting Performance - Energy.gov
- Electrical Contractor Magazine - Understanding IP Ratings in Lighting - ECMag.com
- Lamping - The Impact of Moisture on LED Drivers - Lamping.com
- Facilitiesnet - Maintaining Exterior Lighting Systems - Facilitiesnet.com
- US Department of Energy - LM-80 and TM-21 Explained - Energy.gov