Wall Pack Lights: Gasketed vs Non-Gasketed
Wall pack lights are a staple in commercial and industrial outdoor lighting, providing essential illumination for building perimeters, parking lots, and walkways. A critical design choice in these fixtures is the use of a gasket. This article explores the differences between gasketed and non-gasketed wall packs, examining their construction, performance, and ideal applications to help you make an informed decision for your lighting project.
Introduction to Wall Pack Lights
Wall pack lights, also known as wall sconces or wall-mounted area lights, are designed to be mounted on the exterior walls of buildings. Their primary function is to provide security and visibility in outdoor spaces. They are characterized by a durable housing, a light source (historically HID, now predominantly LED), and a lens or diffuser to protect the internal components and shape the light beam［1］.
The core function of any outdoor luminaire is to withstand environmental stressors such as rain, dust, wind, and extreme temperatures. This is where the concept of ingress protection (IP) ratings becomes crucial. An IP rating, defined by the international standard IEC 60529, classifies the degree of protection provided against the intrusion of solid objects (like dust) and liquids (like water)［2］.
What is a Gasket?
In the context of a lighting fixture, a gasket is a mechanical seal, typically made from a flexible material like silicone, neoprene, or EPDM rubber. It is placed between two mating surfaces—in this case, between the main housing of the light and its lens or cover［3］. When the fixture is assembled, the gasket is compressed, creating a tight, waterproof, and dustproof barrier.
Gasketed Wall Pack Lights
Gasketed wall pack lights are engineered for maximum protection against environmental elements. The gasket creates a sealed enclosure, preventing moisture, dust, and insects from entering the fixture's internal components.
Key Characteristics:
- Superior Ingress Protection: Gasketed fixtures typically achieve high IP ratings, such as IP65, IP66, or even IP67. An IP65 rating means the fixture is dust-tight and protected against water jets from any direction. An IP66 rating offers protection against powerful water jets, and IP67 guarantees protection against temporary immersion in water［2］.
- Enhanced Durability: By keeping corrosive elements like salt spray (in coastal areas) and moisture out, gasketed lights generally have a longer operational lifespan. They protect the LED drivers, wiring, and the LEDs themselves from premature failure.
- Thermal Management: While the seal is tight, well-designed gasketed fixtures incorporate thermal management solutions, such as heat sinks, to dissipate the heat generated by the LEDs, ensuring optimal performance and longevity［4］.
Ideal Applications for Gasketed Wall Packs:
- Harsh Environments: Coastal regions with high salt content in the air, industrial areas with high levels of dust or chemical pollutants.
- High-Moisture Areas: Locations with frequent heavy rain, snow, or high humidity.
- Food Processing Plants & Car Washes: Areas that require frequent, high-pressure washing.
- Security-Critical Zones: Where consistent, reliable illumination is paramount for safety and surveillance.
Non-Gasketed Wall Pack Lights
Non-gasketed wall pack lights, sometimes referred to as "dry-location" or "damp-location" rated fixtures, do not use a compressible seal between the housing and the lens. Instead, they rely on the design of the housing itself to shed water and protect the internal components.
Key Characteristics:
- Breathability: The lack of a complete seal allows for some air exchange between the inside and outside of the fixture. This can help prevent condensation buildup in environments with fluctuating temperatures［5］.
- Cost-Effectiveness: The simpler design and fewer components often make non-gasketed fixtures less expensive to manufacture and purchase.
- Easier Maintenance: In some designs, accessing the internal components for maintenance or replacement can be simpler, as there is no gasket to carefully re-seat.
Ideal Applications for Non-Gasketed Wall Packs:
- Protected Locations: Under eaves, canopies, or covered walkways where the fixture is shielded from direct rainfall.
- Standard Commercial Buildings: Office buildings, retail stores, and warehouses in moderate climates where the fixture is not subjected to extreme weather.
- Budget-Conscious Projects: Where initial cost is a primary concern and the environmental conditions are not severe.
Comparative Analysis: Gasketed vs. Non-Gasketed
| Feature | Gasketed Wall Pack | Non-Gasketed Wall Pack |
|---|---|---|
| Ingress Protection (IP Rating) | High (e.g., IP65, IP66, IP67)［2］ | Low to Moderate (e.g., IP44, IP54)［2］ |
| Durability & Lifespan | Higher, due to superior protection | Moderate, more susceptible to elements |
| Cost | Generally higher | Generally lower |
| Maintenance | Can be more complex | Often simpler |
| Condensation Risk | Low (if designed correctly) | Higher, but breathability can mitigate this［5］ |
| Best For | Harsh, wet, and dusty environments | Protected or moderate environments |
The Role of LED Technology
The shift to LED technology has impacted the design of both gasketed and non-gasketed fixtures. LEDs generate significantly less heat than traditional light sources like metal halide or high-pressure sodium lamps. This reduced heat output lessens the thermal stress on the gasket material, improving its longevity and reliability. Furthermore, the compact size of LEDs allows for more innovative and effective optical and thermal designs within both types of fixtures［4］.
Conclusion
Choosing between a gasketed and a non-gasketed wall pack light depends on a careful assessment of the installation environment, performance requirements, and budget.
For applications demanding maximum reliability and longevity in harsh, wet, or dusty conditions, a gasketed wall pack is the superior choice. Its robust seal provides an essential barrier against the elements, ensuring consistent performance and reducing long-term maintenance costs.
For installations in more sheltered or moderate environments where cost is a significant factor, a non-gasketed wall pack can provide adequate performance at a lower initial investment. Understanding the specific demands of your project is key to selecting the right fixture for the job.
References
- IESNA Lighting Handbook. (2011). Illuminating Engineering Society of North America. https://www.ies.org/standards/lighting-handbook/
- IEC 60529: Degrees of protection provided by enclosures (IP Code). International Electrotechnical Commission. https://webstore.iec.ch/publication/6410
- Oberg, E., et al. (2016). Machinery's Handbook (31st ed.). Industrial Press, Inc. (Section on Gaskets and Seals).
- Aries, M., & Bhandarkar, S. (2018). Solid-State Lighting Reliability. Springer. https://www.springer.com/gp/book/9783319987196
- Boyce, P. R. (2014). Human Factors in Lighting (3rd ed.). CRC Press. (Discussion on luminaire design and environmental interaction).