Wall pack lightsare a staple in commercial and industrial exterior lighting. Designed to provide wide-area illumination for building perimeters, walkways, and loading docks, they are frequently mounted on masonry surfaces［1］. Installing these fixtures on brick facades presents unique challenges compared to wood or vinyl siding. Brick is a hard, brittle material that requires specific drilling techniques, appropriate anchors, and careful waterproofing to ensure a secure and long-lasting installation.
This guide provides a comprehensive, step-by-step approach to installing wall pack lights on brick, covering necessary tools, safety protocols, and wiring best practices.
Tools and Materials Required
Before beginning the installation, it is crucial to gather the correct tools. Drilling into brick without the proper equipment can damage both the masonry and the drill bit.
- Hammer Drill:Unlike a standard drill, a hammer drill uses a pulsating action to pulverize the brick while rotating［2］.
- Masonry Drill Bits:Carbide-tipped bits sized according to your wall anchors (typically 1/4" or 3/8").
- Screwdriver Set / Impact Driver:For securing the fixture.
- Wire Strippers and Cutters:For preparing electrical connections.
- Voltage Tester:To ensure power is off before working.
- Silicone Caulk & Caulking Gun:For weatherproofing entry points.
- Concrete Anchors/Sleeves:Heavy-duty expansion anchors suitable for outdoor use.
- Pencil and Level:For marking drill holes accurately.
Phase 1: Preparation and Safety
1. Power Disconnection
Safety is paramount when dealing with electrical installations. Locate the circuit breaker controlling the installation area and switch it to the "OFF" position. Use a non-contact voltage tester on the existing wires to confirm that no current is flowing［3］.
2. Fixture Assembly
Many modern LED wall packs come with the driver and light engine pre-installed, but some require minor assembly. If your unit has a separate mounting bracket, attach it to the back of the housing now. This makes it easier to hold against the wall while marking drill holes.
3. Positioning
Hold the wall pack against the desired location on the brick facade. Ensure the conduit entry point aligns with your existing wiring path. Use a level to ensure the fixture is perfectly horizontal. Mark the mounting holes on the brick with a pencil.
Note:Avoid drilling directly into the mortar joint if possible. While mortar is softer and easier to drill, it lacks the structural integrity of the brick itself and may crumble over time, causing the heavy fixture to loosen［4］. Always aim to drill into the center of the brick.
Phase 2: Drilling and Mounting
Drilling into brick requires patience and steady pressure. The goal is to create a clean hole for the anchor without cracking the surrounding masonry.
Step-by-Step Drilling Process:
- Select the Bit:Choose a masonry bit that matches the diameter of your concrete anchors.
- Set the Drill:Switch your drill to "hammer mode." This engages the percussive mechanism necessary for breaking up stone and clay.
- Drill the Pilot Hole:Place the tip of the bit on your pencil mark. Start at a slow speed to create a divot, then increase speed while applying firm, steady pressure.
- Depth Control:Drill to the length of the anchor plus about 1/ inch. You can mark the depth on your drill bit with a piece of tape to avoid going too deep.
- Clean the Hole:Remove the drill and vacuum out the dust from the hole. Compressed air can also be used. A dusty hole prevents the anchor from seating correctly［5］.
Securing the Bracket
Insert the concrete anchors (sleeves) into the drilled holes. Tap them gently with a hammer until they are flush with the brick surface. Align the wall pack bracket over the holes and drive the lag screws through the bracket into the anchors. Tighten securely, but avoid over-torquing, which could strip the anchor.
Phase 3: Electrical Wiring
Once the bracket is secure, proceed with the electrical connections. Most commercial wall packs operate on standard voltages (120V-277V), making them compatible with most commercial building wiring.
- Feed the Wires:Pass the supply wires through the conduit and into the wall pack's junction box.
- Strip the Insulation:Strip approximately 3/ inch of insulation from the ends of the supply wires and the fixture wires.
-
Connect the Wires:Match the wires by color code using wire nuts:
- Black (Hot)toBlack (Hot)
- White (Neutral)toWhite (Neutral)
- Green or Bare Copper (Ground)toGreen (Ground)［6］
- Secure Connections:Tuck the wires neatly into the junction box to prevent pinching when the cover is closed.
Phase 4: Weatherproofing and Finalizing
Exterior lighting must withstand rain, snow, and humidity. Proper sealing is critical to prevent water ingress, which can short-circuit the LED driver.
Waterproofing Techniques
Apply a generous bead of clear silicone caulk around the perimeter of the mounting bracket where it meets the brick. Additionally, seal the entry point where the conduit enters the fixture. This prevents moisture from wicking behind the fixture and damaging the brick or the electrical components［7］.
Installing the Light Source
If your wall pack uses replaceable bulbs (like traditional HID or CFL), install them now. However, most modern installations utilizeintegrated LED Wall Packs, where the LEDs are built into the fixture. For these units, simply attach the lens or cover plate according to the manufacturer's instructions.
Restore power at the circuit breaker and test the light.
Maintenance and Optimization
To maximize the lifespan of your exterior lighting, consider the following maintenance tips:
- Regular Cleaning:Dust and grime can accumulate on the lens, reducing light output (lumens). Clean the fixture periodically with mild soap and water.
- Photocell Checks:If your wall pack is equipped with a dusk-to-dawn photocell, ensure the sensor is not obstructed by vegetation or other structures, which can cause erratic operation［8］.
- Inspect Seals:Annually check the silicone caulking for cracks or peeling and reapply if necessary to maintain the IP (Ingress Protection) rating.
By following these guidelines, you can ensure a safe, professional, and durable installation of wall pack lights on brick facades, enhancing both the security and aesthetics of your commercial property.
References
［1］U.S. Department of Energy - Outdoor Lighting Basicshttps://www.energy.gov/energysaver/outdoor-lighting
［2］The Family Handyman - How to Drill Into Concrete and Masonryhttps://www.familyhandyman.com/project/how-to-drill-into-concrete-and-masonry/
［3］Occupational Safety and Health Administration (OSHA) - Electrical Safetyhttps://www.osha.gov/electrical
［4］This Old House - How to Anchor Objects to Brickhttps://www.thisoldhouse.com/masonry/reviews/how-to-anchor-objects-to-brick/
［5］Bob Vila - Drilling Into Brick: A Step-by-Step Guidehttps://www.bobvila.com/articles/drilling-into-brick/
［6］National Electrical Code (NEC) - Wiring Color Codeshttps://www.nfpa.org/news-blogs-and-articles/blogs/2021/03/16/nec-basics-grounding-and-bonding
［7］Energy Star - Sealant and Weatherstripping Guidelineshttps://www.energystar.gov/seal-and-insulate
［8］DesignLights Consortium (DLC) - Outdoor Lighting Controlshttps://www.designlights.org/outdoor/
