If your facility needs an exit sign with integrated emergency lights that can take abuse and stay compliant, this guide explains when to specify a steel (metal) exit sign & emergency light combo, how to size it, and which options matter. It’s an educational overview—not a product listing—so it won’t compete with the parent category. When you’re ready to compare models, head to the collection below.
Last updated: October 2025
Overview & Positioning (Non-Competing Intent)
This article is written to support—not replace—the parent collection for steel exit sign & light combos. Our goal is to help you decide when a steel or broader metal exit light combo is the right call, how to select features, and how to install for code-clean inspections. We intentionally avoid “shopping page” language so this post does not compete with the category’s primary transactional keyword. Think of this as the engineering & facilities how-to: durability, abuse-resistance, lamp head sizing, code nuances, and maintenance strategy.
At a high level, metal combos combine a UL 924 exit sign and two emergency light heads in one rugged housing. Steel cabinets resist impact and tampering better than thermoplastic. If you’re planning a school, stadium, warehouse, transit bay, or any space where fixtures get bumped, prodded, or vandalized, steel or die-cast aluminum enclosures often pay for themselves in fewer replacements and cleaner inspections.
When to Specify Steel / Metal Exit Light Combos
Use steel or other metal-bodied combos when one or more of the following is true:
- High-abuse risk: Gymnasiums, arena concourses, loading docks, correctional/behavioral health, transit corridors, and public stair towers. Metal housings and tamper-resistant hardware reduce damage from impacts and prying.
- Frequent contact or moving equipment: Warehouses with forklifts, maintenance corridors with carts/ladders, or any tight pathway where units get bumped.
- Security-sensitive zones: Areas where broken plastic could become a hazard, or where fixtures must be harder to remove or weaponize. Metal combos paired with security hardware and vandal guards help mitigate risks.
- Jurisdictional requirements: In some cities (e.g., NYC; often Chicago), metal exit signage/combos are required or strongly preferred for code approval. If in doubt, ask your AHJ early.
- Lifecycle cost focus: Facilities where replacing cracked plastic housings and relabeling submittals costs more over time than a sturdier metal unit up front.
Scenario: A middle school upgrades exit signage in the gym and main stairs. The previous thermoplastic combos cracked multiple times per year. Switching to steel reduces breakage, keeps heads aimed, and decreases inspection punch-list items.
Feature Deep Dive: Housing, Lamps, Power, Options
Here’s what matters most on a metal exit light combo spec:
Housing & Finish
- Material: Powder-coated steel for maximum stiffness and impact resistance. Die-cast aluminum offers excellent durability with lower weight and better corrosion resistance for damp/coastal interiors.
- Doors / Covers: Hinged or front-access panels simplify testing and battery swaps. Choose tamper-resistant screws where vandalism is likely.
- Color: White and black are common; gray or custom finishes help blend with industrial palettes. Letter color is governed by code (often red; confirm with the AHJ).
Emergency Lamp Heads
- Adjustability: Heads should lock after aiming to hold alignment. In high-traffic areas, consider slightly wider beam heads for better doorway wash.
- Output: Typical combo heads range ~3–10 W each. Your lumen needs depend on mounting height and target foot-candles—see Sizing & Spacing.
- Guards: Add vandal guards where impact is likely; they preserve lenses/optics without blocking output.
Power System & Battery
- Input: Universal 120/277 VAC with brownout protection and low-voltage disconnect.
- Battery chemistry: Ni-Cd is common and economical; LiFePO4 offers longer life, lighter weight, and faster recharge at a higher price point.
- Runtime: UL 924 requires a verified 90-minute battery discharge supporting both the sign legend and both lamp heads.
- Self-diagnostics: Recommended for large campuses—automates monthly/annual tests and logs faults (battery, lamps, charger).
- Remote-capable: Some metal combos provide extra wattage to power remote heads elsewhere on the circuit; great for long corridors or to illuminate an additional door.
Configuration & Wording
- Faces: Single-face for walls; double-face for center-of-corridor/end mount.
- Arrows: Field-applied or knockouts—match your life-safety plan. Keep a redline set for as-built documentation.
- Language & custom legends: Some facilities require EXIT/SALIDA or special wording; confirm availability on metal housings early.
Sizing & Spacing the Emergency Lamps (Quick Method)
The combo’s lamp heads must deliver adequate illumination at the floor along the egress path. While full photometric layouts are ideal, you can do a quick, conservative check:
- Identify the target zone: Typically the door threshold and the first 10–20 feet of egress path just beyond the door.
- Mounting height & beam: Note the installed height (often 7–8 ft AFF) and whether your heads are narrow or wide beam.
- Choose head wattage: If the path is short and reflective (light walls/ceilings), 2×3–5 W may suffice. For taller ceilings, dark finishes, or “wash down the stairs,” consider 2×7–10 W.
- Aim for uniformity: Aim heads to avoid hotspots on walls while raising average foot-candles on the floor; small lateral offsets help smooth the pattern.
- Validate: Perform a 90-minute test with a light meter and document readings at several floor points (doorway, 5 ft, 10 ft). Record in your commissioning log.
Pro tip: If the doorway wash is acceptable but the corridor fades quickly, a remote-capable steel combo plus one or two remote heads farther down the hall often beats replacing the entire unit with a much higher-wattage combo.
Installation & Mounting Best Practices
- Support the weight: Steel cabinets are heavier than plastic. Use appropriate anchors and ensure the junction box and substrate can support the load.
- Mounting method: Wall/back mount where possible; use end/flag brackets or ceiling canopies for center-of-corridor visibility. Confirm the final arrow direction before fastening.
- Conduit & drip loops: In damp areas, keep entries from wicking moisture. Use listed hubs/gaskets per rating.
- Access for testing: Keep the test button and status LED visible from the floor. Don’t bury the face behind door hardware or signage.
- Secure the heads: After aiming, tighten fully; note aim directions in closeout docs so maintenance can restore them after a bump.
- Label the circuit: Identify normal/emergency feeds where dual-circuit is used; include a small as-built sketch in the panel schedule.
Environmental Ratings: Damp, Wet, NEMA/IP
Most metal combos are indoor/damp-location listed. If installed outdoors or where water jets/spray are present, you need a wet-location or NEMA/IP-rated model. Look for:
- Damp Location: Standard interiors with occasional condensation; not direct spray.
- Wet Location: Gasketed, sealed designs for weather-exposed areas and washdown zones.
- NEMA 3R/4/4X or IP65/66: Higher protection from water/dust; 4X adds corrosion resistance for harsh environments.
When in doubt, select the higher rating for longevity—especially near exterior doors, docks, or unconditioned stairwells that see wind-driven rain or frequent mopping.
Compliance Notes: UL 924, NFPA 101, NYC & Chicago
- UL 924: Verifies automatic transfer to battery power and a 90-minute discharge for the sign and lamps. Check the nameplate and run a full acceptance test.
- NFPA 101 / IBC: Requires continuous, reliable exit marking and minimum egress illumination. Confirm placement, heights, and arrow directions match the life-safety plan.
- NYC & Chicago: Commonly require metal housings and specific letter sizes/colors/legends. If your project is in these jurisdictions, select models explicitly listed as compliant.
- Self-testing: Many AHJs accept self-diagnostic logs for monthly/annual tests. Where not accepted, use the feature to supplement—but still perform witnessed tests as required.
TCO & ROI: Paying More for Metal—When It Pays Back
Steel combos cost more upfront than thermoplastic, but they often lower total cost where damage is likely. Fewer cracked housings, fewer mis-aimed heads, and fewer emergency “fail” tags during inspections mean fewer truck rolls and replacements. Campuses that move from plastic to steel in gyms, garages, and loading areas routinely report fewer service tickets and longer fixture lifespans.
Common Mistakes to Avoid (Checklist)
- Speccing plastic in a high-abuse zone—use metal where impacts/tampering are likely.
- Undersizing lamp heads—validate with a meter; consider remote-capable if the path is long.
- Forgetting wet/NEMA rating—standard damp units will fail outdoors or under washdown.
- Blocking visibility—ensure the legend and test LED are unobstructed from normal viewing angles.
- No documentation—log the 90-minute test, head aim directions, and battery install date.
Editable Spec Language (Copy/Paste)
Provide steel (metal) exit sign & emergency light combo units, UL 924 listed, suitable for [DAMP/WET] location as scheduled.
Housing: powder-coated steel (or die-cast aluminum), tamper-resistant hardware.
Input: 120/277 VAC. Transfer: solid-state, automatic.
Battery: [Ni-Cd / LiFePO4], 90-minute minimum runtime supporting legend + both heads.
Legend: [RED/GREEN], [single/double-face], field-applied chevrons per life-safety plans.
Lamps: two adjustable LED heads, output sufficient to achieve code illumination at floor per NFPA 101 along the egress path.
Options: self-diagnostics, remote-capable output [XX W], dual-circuit [as required].
NYC/Chicago compliant models where required by jurisdiction.
Install per manufacturer instructions; aim heads and document acceptance (metered readings, 90-min discharge log).
FAQ
Will this compete with the parent collection keyword?
No. This post focuses on when and how to specify steel/metal exit light combos (durability, sizing, compliance)—not on shopping or model comparisons. It routes readers to the collection for products but avoids transactional language.
Steel vs. die-cast aluminum—how do I choose?
Steel is the stiffest/heaviest and most impact-resistant; die-cast aluminum is very durable too, with lower weight and better corrosion resistance. For coastal/damp interiors, aluminum often wins. For pure abuse resistance and cost control, steel is the classic choice.
Can one combo power extra remote heads?
Many remote-capable metal combos can. Check the remote wattage budget; ensure the sum of the EXIT legend, on-board heads, and all remote heads stays within the 90-minute battery rating with margin.
Do I need self-diagnostics?
For multi-building sites or tight staffing, yes—it automates monthly/annual tests and flags battery/lamp faults via status codes. Always confirm your AHJ accepts self-test logs (many do) and keep a manual test routine as backup.
What about NYC or Chicago projects?
Use models specifically approved for these jurisdictions (metal housings, required letter size/color, and legend style). If your submittal mentions NYC/Chicago, select the appropriate “city-approved” metal combo line item.