Replacing boxes in Brick

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mhulbert

Senior Member
Location
Chico, CA
A customer has an outdoor BBQ/Bar made out of concrete with brick over it and tile counters. There are 4-5 1 and 2 gang aluminum bell boxes (WP) embedded/grouted in the brick with sch 40 PVC going into them. Well, they are all corroding inside (near a pool), to the point that the aluminum is disolving into powder and the screws don't stay into the steel plates due to rust, etc. Customer (and myself!) would like to replace these with a longer lasting setup.

Do you guys have any ideas on how to extract these old boxes out, put something new in, and connect the PVC to them? I am at a loss on what to do. I will probably have to get the grout re-done. Oh yeah, money is not much of a problem, he wants it done right, so is there an industrial product or something esoteric I'm missing? Any creative ideas would be excellent. I really don't want to have to rip up a ton of brick and concrete just to replace these boxes. Shame on the original guy for using aluminum in concrete!

Thanks for any help, Mike
 
Re: Replacing boxes in Brick

Yes, aluminum in concrete is the problem. I don't think anything short of a magic wand is going to allow you to replace those boxes with PVC without breaking up at least some of the masonry. The other option is to surface mount everything.

-Hal
 
Re: Replacing boxes in Brick

I'm assuming there's 1/2" threaded pvc connectors hopefully entering the back of the boxes. I think if that's the case you can drill around the connector after the rest of the box is out and you can spin that part off of the connector. I also think pvc boxes would last longer there but I don't know about them fitting in the same hole as the aluminum did.
 
Re: Replacing boxes in Brick

I guess we thought the same thing Hal. :)

I've had some luck with a roto hammer, masonry bits and a chisel on things like that. Good thing money's no object. :)
 
Re: Replacing boxes in Brick

Unfortunately, some of the PVC comes in the top/bottom of the boxes! I think I'm going to get in touch with a brick guy to see how hard it is to replace this brick. I will probably have to take some out all around each box. At least it's not ceramic tile!

For PVC boxes, what would you use? What's the sturdiest/most heavy duty one out there?

Stupid question, but I don't have much experience with the PVC stuff

I was thinking of replacing with this, but again, it's cast aluminum, so I think the pool chlorine will get it:
HD Commercial Mortar In Box

Thanks, Mike
 
Re: Replacing boxes in Brick

I beleive Carlon makes pvc boxes. I would let the mason do the demo work if it were me.
 
Re: Replacing boxes in Brick

... so I think the pool chlorine will get it

It's not the chlorine but the alkali in the mortar. You never want to put aluminum in or under concrete. It turns into toothpaste!

-Hal
 
Re: Replacing boxes in Brick

mhulbert What about a grinder or the local concrete cutting co.,those saw blades are fairly thin.Cut right thru the pvc connector,get the box out,use something like a right angle "Dremmel" tool to remove the pvc pipe from inside of the connector,I know they make a pvc fitting that has a collar on the end of it { kind of like a threadless pvc chase nipple }---slide your new box into the hole, glue fitting into the old connector????
 
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