Box Fill Calculations

By
Keith Lofland
-
January 31, 2017
0
7557

One of the most frequently encountered Code violations, in my experience,

would have to be those concerning box fill requirements. More conductors,
devices, fittings, etc., are often installed in a box than what that particular
box was designed and listed to contain. Unfortunately, these over-crowded
boxes are all too common at both residential and commercial applications.

One might say, “OK, what’s the big deal; what’s the harm?” When put to
work carrying the load they are intended to carry (such as a lighting load),
the enclosed conductors produce heat from current flow associated with
these loads. These conductors must have ample free space to allow proper
dissipation of heat from the conductor to not cause damage to the
surrounding insulation of these said conductors. A crowded elevator heats
up fairly quickly because you and the other heat radiators (bodies) don’t
have ample room to dissipate the produced body heat. The same principle
applies to conductors enclosed in a confined space, such as a switch box.

The National Electrical Code (NEC) contains sufficient rules and

requirements that apply to box fill calculation requirements. Most of these
requirements can be found in Article 314 (Outlet, Device, Pull, and Junction
Boxes; Conduit Bodies; Fittings; and Handhole Enclosures). Let’s look
closer at these requirements for box fill calculations.

General Rules for Boxes

The Code includes general requirements for boxes, such as sizing and
support provisions. All boxes (enclosures) must be large enough to provide
for sufficient free space for all conductors and devices that will be enclosed
within them to prevent overcrowding and possible physical damage when
the devices or splices are installed or completed. Outlet boxes that do not
contain devices or utilization equipment are permitted to have an internal
depth of less than 12.7 mm (½ in.). Boxes that enclose large equipment
are required to have a depth that is not less than the depth of the
equipment plus 6 mm (¼ in.). Large equipment is defined as devices or
utilization equipment that projects more than 48 mm (1 ⅞ in.) rearward
from the mounting plane of the box [see NEC 314.24].

Other boxes that enclose devices or utilization equipment are to be sized

based on the supply conductors that supply the devices or utilization
equipment (see Table 1). In completed installations, each box is required to
have a cover, faceplate or luminaire canopy. One reason behind this rule is
that if a failure occurs, it is likely to occur at a joint, splice, or termination.
This type of failure often starts with a loose connection, and may result in a
great deal of heat and be accompanied by arcing. A box or conduit body
reduces the likelihood of adjacent combustible materials being ignited by
heat or arcing (see NEC 314.25 and 410.22).
 Table 1. Minimum
internal depth requirements for outlet and device boxes with enclosed
devices or utilization equipment
Screws used for the purpose of attaching covers, or other equipment, to
the box are required to be either machine screws matching the thread
gauge or size that is integral to the box, or must be in accordance with the
manufacturer’s instructions. This means the use of drywall screws or sheet-
metal screws for attaching covers, luminaires, or other equipment to boxes
is unacceptable. This crude practice can result in damage to the box and
inadequate support of the attached cover, luminaire, or equipment itself
[see NEC314.25, 404.10(B), or 406.5].

Metal boxes, covers, or cover plates are required to be

grounded. NEC 250.110 specifically requires that exposed non–current-
carrying metal parts of fixed equipment be grounded by connection to the
equipment grounding conductor. Specifically, 250.110(5) requires that a
metal box or enclosure be grounded if supplied by a metal raceway, metal-
clad or metal-sheathed cable, or other wiring method that includes an
equipment grounding conductor. The attachment of a metal cover or plate
to an effectively grounded enclosure or device usually fulfills this
requirement [see NEC 250.110(5), 314.4, or 314.28(C)].
 Figure 1. Volume
of boxes is based on total volume of assembled sections including plaster
rings or covers with marked volumes.

Metal boxes usually have a means for connecting the box to an equipment
grounding conductor. Typically, this consists of a 10-32 tapped hole. Some
nonmetallic boxes contain an integral means for bonding switches and
metal faceplates to the equipment grounding conductor. The bonding
means may be a metal strap or band that links the device mounting screw
to an equipment grounding terminal [see NEC 314.40(D)].

Box Volume Calculations

Volume of a box is the total volume in cubic millimeters or cubic inches of
the assembled sections. Where used, the space provided by plaster rings,
domed covers and extension rings that are marked with their volume in
cubic inches is included. If the extension ring is made of metal and
corresponds to a size listed in NEC Table 314.16(A), the appropriate
volume for that size box is used as the volume of the extension ring. Total
volume is the volume of the box plus the volume of any attached plaster
rings, extension rings, or domed cover.

This total volume (space) determines the number and size of conductors
and wiring devices permitted to be contained in the box. Conductors,
internal clamps, support fittings, barriers, and devices such as switches and
receptacles take up space within the box. The Code assigns to each
conductor, clamp, support fitting, barrier, device, and equipment grounding
conductor an associated volume allowance. This volume allowance is listed
in cubic inches or cubic centimeters. NEC Table 314.16(B) lists the volume
allowance as a function of conductor size. The volume allowance for each
conductor, clamp, support fitting, barrier, device, and equipment grounding
conductor is added together. The box must have a volume that equals or
exceeds the total volume required for the contained items.

Photo 1. Double
4-Square metallic box with plaster extension ring
Where a box is provided with one or more securely installed barriers, the
volume is to be allocated to each of the resulting spaces. Each barrier, if
not marked with its volume, is to be considered to take up 8.2 cm 3 (1∕2 in3)
if metal, and 16.4 cm3 (1.0 in3) if nonmetallic. These volume considerations
for barriers were added to the 2017 NEC [see NEC314.16(A)]. Each space
within a box installed with a barrier must be calculated as separate boxes
on each side of the barrier [see NEC 314.16(B)].

Sometimes, more conductors end up in boxes than were originally

intended. For example, the conduit may be of sufficient size for a new
circuit; however, the pull or outlet box may not have sufficient volume.
Where practicable, an extension ring that is the same shape as the box can
be installed; this will add the required additional space so the original box
does not have to be replaced. Sometimes it is necessary to replace the
original box with a deeper metallic or nonmetallic box to achieve the
required volume of space [see NEC 314.16(A)].

Figure 2. Box
volume for standard boxes

Standard Metal Boxes

The Code covers the maximum number of conductors permitted within a
standard metal box. These boxes may have their cubic millimeter (cubic
inch) capacity marked on the box where the capacity is larger than given in
the volume allowance table, but that is not an NEC requirement.

Table 314.16(A) in the NEC provide box dimension and trade size in inches
for standard metal boxes. The minimum cubic millimeter (cubic inch)
capacity for each standard size metal box is given along with the maximum
number of conductors of sizes 18 AWG through 6 AWG permitted in the
box. As shown in the table, the number of conductors permitted applies
only where all conductors are the same size. Where a box contains
conductors of different sizes, the required volume of the box must be
calculated.

A calculation is also required if the box contains devices, clamps, barriers,

or support fittings. No volume allowances are required for small fittings
such as locknuts and bushings [see NEC 314.16(B)].

Other Boxes (Nonmetallic Boxes)

Metal boxes may be manufactured in sizes other than those listed
in NEC Table 314.16(A). This type of box is called a non-standard box.
Nonmetallic boxes made in custom sizes are called non-standard as well, if
their dimensions different from those in NEC Table 314.16(A). All non-
standard boxes must have their cubic millimeter (cubic inch) capacity
durably and legibly marked by the manufacturer on the inside of the box.
Additional markings on nonmetallic boxes may include the type of fire-
resistive wall, floor, or ceiling assembly for which the box is suitable. A box
listed for the support of a luminaire or lampholder in a ceiling shall be
designed for the purpose and is required to support a luminaire weighing a
minimum of 23 kg (50 lb). Boxes used at luminaire or lampholder outlets
on a vertical surface or in a wall are required to be designed for the
purpose. They are also required to be marked by the manufacturer on the
interior of the box itself to indicate the maximum weight of the luminaire
that is permitted to be supported by that box on a vertical surface [if other
than 23 kg (50 lb)]. Vertical surface or wall-mounted device boxes are
permitted to support luminaires that weigh not more than 3 kg (6 lb).
These device boxes may not be marked as being suitable for luminaire
support since that is not their primary purpose. The luminaire or its
supporting yoke must be secured to the box with at least two 6-32 screws
[see NEC 314.27(A)].

Figure 3.
Conductor fill for nonstandard other boxes
Requirements for determining the maximum number of conductors
permitted in non-standard or nonmetallic boxes are given
in NEC 314.16(B). The individual volume of each conductor, clamp, and
fitting is provided in this volume allowance table. The minimum volume of
the box is the total of the individual volumes required for each conductor,
device, barrier, or fitting.
A typical nonmetallic, single-gang device box typically used for new
construction does not have internal clamps. The openings on a single-gang
nonmetallic box are considered knockouts. As a result, no volume
allowance for clamps is required on a single-gang nonmetallic box if the
installation complies with 314.17(C), Exception. Multiple-gang device
nonmetallic boxes and round or octagonal boxes have internal clamps.
These clamps may be field-installed or incorporated into the box by the
manufacturer. A single volume allowance is made for one or more internal
clamps that are present in the box. The volume allowance for clamps that
are an integral part of the box construction is included in the marked
volume of the box. This requirement will be discussed in further detail later
in this article.

Figure 4. Fixture
wire luminaire conductors entering a ceiling-mounted box

Box Fill Calculations

The Code provides the method for determining the minimum cubic
millimeter (cubic inch) volume required in non-standard or nonmetallic
boxes. This same method is also used to determine the minimum volume of
standard metal boxes that have more than one size of conductors or any
devices installed in them. This method requires the addition of all the
allowances required for various items, and this sum then becomes the
minimum volume required for the box. At that point, the size of a standard
(metal) box or nonmetallic box with a cubic inch volume that equals or
exceeds the volume required can be determined.

Table 2. Box volume calculations,

standard and nonstandard boxes

As stated previously, no allowance is required for small fittings in boxes

such as for locknuts, bushings and parts of cable connectors that are inside
single-gang nonmetallic boxes. Cubic millimeter (cubic inch) volume for
each item that must be considered is given in NEC Table 314.16(B). This
table gives the cubic millimeter (cubic inch) volume allowance required for
conductors from 18 AWG through 6 AWG.

Conductor Fill
The Code requires each conductor that originates outside the box and
terminates or is spliced within the box to be counted once. Each conductor
that passes through the box without splice or termination is also required to
be counted once. A looped, unbroken conductor 300 mm (12 in.) or longer
is counted as two conductors. A conductor which originates in, and of which
no part leaves the box, is not required to be counted. These are often
jumpers or “pigtails” to wiring devices.

An exception to this rule applies to the conductors that are part of the
luminaire wiring. It permits equipment grounding conductor(s) or not more
than four fixture wires smaller than 14 AWG, or both, to be omitted from
the fill calculations. The conductors must enter a box from a domed
luminaire or similar canopy, and are required to terminate within the outlet
box.
 Photo 2. Single-
gang nonmetallic box with Type NM cable with box fill calculated by the
volume required per conductor, device, clamps, etc.

Clamp Fill
The Code provides information on the volume required for clamp fill. Where
one or more internal cable clamps, whether factory or field-supplied, are
present in the box, a single volume allowance in accordance with NEC Table
314.16(B) is required to be made based on the largest conductor present in
the box. This section requires a single volume allowance for all the clamps
that are internal to the box, regardless of the number of clamps. Volume
allowance is required for nonmetallic boxes (other than single-gang
nonmetallic boxes) with integral cable clamps. Before the total box volume
can be determined on nonmetallic boxes (other than single-gang boxes),
the manufacturer is required to remove the internal clamping mechanism;
then total box volume is determined by a nationally recognized testing
laboratory (NRTL). Single-gang boxes are determined to have knockouts
rather than cable clamps, so no deduction is required for cable clamps for
single-gang nonmetallic boxes when securing nonmetallic-sheathed cable
within 200 mm (8 in.) of the box as allowed by NEC 314.17(C) Exception.
No allowance is required to be made for a cable connector with its clamping
mechanism outside the box. A clamp assembly listed and marked for use
with specific nonmetallic boxes that incorporates a cable termination for the
cable conductors have been introduced to the electrical industry in recent
years. Conductors that originate within the clamp assembly shall be
included in conductor fill calculations as though they entered from outside
the box.

Support Fittings Fill

Where one or more fixture studs or hickeys are present in the box, a single
volume allowance is required to be made for each type of fitting in the box.

Where both a fixture stud and a hickey are present in the box, two volume
allowances must be made. One volume allowance is made for the fixture
stud; the other, for the hickey. Each volume allowance is based on the
largest conductor present in the box [see NEC 314.16(B)(3)].
 Photo 3. Same
single-gang nonmetallic box with conductors pulled out of the box for ease
of counting total conductors.

For our younger generation of readers, a fixture stud is a fitting that

mounts to the top of the box, usually inserts through the knockout of a
metal box, and is threaded to accommodate the fixture stem. A hickey is a
fitting that can be described as a coupling that has threads the same size
as the fixture stem and has an oval-shaped hole on one or more sides for
the fixture wires to exit inside the box. The hickey is usually threaded onto
the fixture stud with the fixture stem threaded into it. These fittings, while
used in many older, existing installations, have fallen out of popular use.
Nowadays, a luminaire strap or hanger strap is secured to the box with two
8-32 screws, and the luminaire is mounted to the strap.

Device or Equipment Fill

Minimum requirements for device or equipment fill are also provided in the
Code. A double volume allowance is required for each yoke or strap
containing one or more devices or equipment. Table 314.16(B) gives the
volume allowance. This volume allowance is based on the largest conductor
connected to a device(s) or equipment supported by that yoke or strap.
This requirement applies to devices such as switches, timers, dimmers, and
receptacles. The word equipment is intended to include items like pilot
lights.

Table 3. Volume
allowance required per conductor Table 314.16(B)
Each device or equipment is considered individually where more than one
item is contained in the box. For example, if a switch has 14 AWG wire
connected to it, a volume allowance of 2 x 2.0 cubic inches or 4 cubic
inches is required. If a receptacle has 12 AWG wire connected to it, a
volume allowance of 2 x 2.25 or 4.5 cubic inches must be made for that
particular device.

Any device or utilization equipment wider than a single 50 mm (2 in.)

device box is required to have a double volume allowance provided for each
gang required for mounting. This would apply to a device such as a dryer
receptacle that would require two yokes for mounting. A device such as this
would be required to be counted as four conductors based on the largest
conductor connected to such device.

Figure 5.
Conductor fill requirements for boxes with multiple gangs

Equipment Grounding Conductor Fill

Requirements for equipment grounding conductor and equipment bonding
conductor fill are covered in the Code. A single volume allowance is made
regardless of the number of equipment grounding conductors installed. The
allowance is based on the largest equipment grounding or equipment
bonding conductor present in the box. Where an additional set of
equipment grounding conductor(s) is present in the box, such as an
isolated equipment grounding conductor for an isolated receptacle as
permitted by NEC250.146(D), an additional volume allowance is required
based on the largest isolated equipment grounding conductor(s) in the
additional set.

Conclusion
As this article has demonstrated, several factors must be taken into
consideration when determining the maximum number of conductors a box
is allowed to contain without creating a Code violation. Are cable clamps
involved? How many devices will be installed in the box along with these
conductors at final installation? These are just some of the questions that
must be answered to arrive at a compliant installation for box fill.
Deduction for cable clamps, devices, barriers, etc. is also why you cannot
go with the simple information provided in Table 314.16(A) for the
maximum number of conductors a particular sized box can contain. As
stated previously, these contained conductors must have ample free air
around the conductor and its insulation to allow proper dissipation of self-
generated heat from the conductor itself.

Proper box fill calculations is a vital cog in the safe installation of the
electrical wiring installed in commercial and residential buildings. I can
testify that checking for box fill provisions will eventually become second
nature to the inspector and the installer if they make it a normal part of
their daily inspection or installation routine. It might be cumbersome at
first, but eventually, a box that contains too many conductors will jump off
the wall at you if you make box fill calculations an everyday normal
practice.