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Old 09-15-2017, 09:26 AM   #1
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Default Flush Receptacle in Block Wall

Customer wants to add a flush mounted receptacle to an existing block wall. I've drilled, punched, etc. through block walls but never had to cut out for a box.
What's the best way to cut out the block for a box so there is little damage?
Also, how to seat the box in the wall, construction adhesive?
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Old 09-15-2017, 09:33 AM   #2
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Make the cut out with a grinder. Hammer and chisel it clean.

Sometimes there will be some meat behind the box to Tapcon into. Or sometimes you can Tapcon thru the side of the box.

How are you getting the wiring to the box?
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Old 09-15-2017, 09:39 AM   #3
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Drill a bunch of 1/4 in holes without the hammer drill, then chisel out your opening. If you are able to use a Tapcon to secure the box and then use your choice of adhesive.
One oversized plate if you need it and go collect your money.

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Old 09-15-2017, 09:42 AM   #4
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Quote:
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Make the cut out with a grinder. Hammer and chisel it clean.

Sometimes there will be some meat behind the box to Tapcon into. Or sometimes you can Tapcon thru the side of the box.

How are you getting the wiring to the box?
I can get to the top of the wall and drop the wire down.
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Old 09-15-2017, 09:44 AM   #5
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I can get to the top of the wall and drop the wire down.
Just make sure you could get down the whole way before cutting out the box. Sometimes there are globs of mortar blocking the way
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Old 09-15-2017, 09:44 AM   #6
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If this is a CMU wall, be sure it is not poured with insulation! If you punch a hole in a filled wall, you will have a mess on your hands quickly if you are not prepared.

I have drilled a small hole near the top of the box cut out and sprayed expanding foam in there, let it dry, then go back and cut the box in.

How are you getting the conductors to the box? Edit: I see this has been asked and answered already.
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Old 09-15-2017, 09:53 AM   #7
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Quote:
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Just make sure you could get down the whole way before cutting out the box. Sometimes there are globs of mortar blocking the way
I was going to look and stick my fish rod down before I cut out the block.

My heart is fluttering just having you post in my thread!
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Old 09-15-2017, 10:17 AM   #8
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Hack is right on the money here with the grinder cut and the rest of his commentary.
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Old 09-15-2017, 11:34 AM   #9
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My heart is fluttering just having you post in my thread!
I'm sensing a little sarcasm


I told you I was sorry for yelling at you for putting garbage in the trench
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Old 09-15-2017, 02:39 PM   #10
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I use an angle grinder with a diamond blade to make the box outline. Chisel out the center and try to taper the cmu wider in the direction into the wall. Bakelite box to finish


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Old 09-15-2017, 03:15 PM   #11
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Grinder here too...sucks when the block is filled thou
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Old 09-15-2017, 04:48 PM   #12
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This situation is COMMON in Europe... so there are plenty of (British) videos on the technique out their on YouTube. ( They are way into brick... with compound walls being common: CBU in the core -- then a void -- then a classic red brick exterior. It's the land of the free mason. )

They are quick and short... and worth your money to watch. ( Since they're free. )

This headache is so common in Europe that trick tooling has been developed.

But it, the trick stuff, is virtually unknown in the USA. It figures to cost a mint.
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Old 09-15-2017, 05:29 PM   #13
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In the olden days we would just use a hammer. Make a couple of holes toward the center and work your way out to where it is just shy of the box OD, then bang a round cornered handy box into the wall.

Since this is 2017, diamond blade/grinder. Make the hole tight and whatever box you use may jam in and stay put. You can use a cut in box but you need longer screws for the tabs. There are a number of ways (caulk, foam, shims) to secure the box if the hole is too large. Wood shims work best but they may not be allowed.


No grinder? No problem. Just use a hammer and some finesse.


And, drop jack chain down the wall for a fish method.
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Old 09-15-2017, 05:42 PM   #14
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I like these for cmu walls.

http://www.aifittings.com/catalog/sp...4-boxes/FSCB24
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Old 09-15-2017, 05:44 PM   #15
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What I always did was to make sure I could get down the cell in the block wall first.
Then cut out for the box ( just big enough for the box), Fished the cable/MC/BX/Greenfield dow the wall and out of the cut out.
Then I installed the Cable/MC/BX/Greenfield into the box.
Then I filled the cell with block pieces/rocks up to about 3 inches below the cut out.
Then I filled the entire open cell with mortar ( cement) as much as I could fit the hole.
I mean I completely filled the cut out, below ,to the sides, and all basically your closing the hole with mortar. Then I worked the box into the mortar while pulling the Cable/MC/BX/Greenfield up the wall, which allows the box to go in.(I used to be able to do this all by myself )
Once the box is in the wall I dressed up around the box with mortar ( cement). Came back next day or a few hours later to trim out.
I installed both masonry ( mud boxes) boxes, 1900 boxes, utility boxes using this method and have never had a loose one
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Old 09-15-2017, 07:41 PM   #16
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I didn't know they made those.
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Old 09-15-2017, 09:21 PM   #17
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Quote:
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I'm sensing a little sarcasm


I told you I was sorry for yelling at you for putting garbage in the trench
No sarcasm!

But you should have forgotten about the trench by now!
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Old 09-15-2017, 10:37 PM   #18
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Cut hole, fish, put the box in, wedge it and expado foam the **** out of it.
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Old 09-16-2017, 05:56 AM   #19
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Has anyone tried the carbide or diamond reciprocating saw blades to cut block?


Watching that video, with two starter holes drilled in the corners, that looks faster than using a grinder and probably less mess. I imagine you are going to eat a lot of blades but if it's not really large count it probably doesn't matter much.
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