A long-lasting and secure channel letter installation takes a substantial amount of knowledge and experience. This article details some of the key considerations installers review prior to (and during) a letter installation.
Site Survey
A site survey is the typical preliminary installation task. This is often performed by one of the company’s sales personnel or a member of the company’s installation crew. Several items are inspected during this step.
Gary Schultz at Artcraft Signs in Denver, Colorado says that his company tries to always check for optimum letter mounting placement.
“The best location partially depends on access for wiring of the letters or sign,” he says. “We may need to adjust the proposed placement of the letter sign to get to the optimum position.”
Electrical access alone can impact the installation cost estimate.
Dave Curry of Star Sign and Banner in Cedar City, Utah mentions, “We always check the physical access to the letter mounting area, as well as the run to the electrical power supply.”
Installers also note that it’s beneficial to make a close inspection of the actual wall surface. A closer examination will sometimes reveal that a second wall material exists behind a surface-level façade, or it may show that a material requires special mounting procedures.
Keith Blumenfeld of M & J Sign Company in Albuquerque, New Mexico adds, “If the customer must have an above roofline install, you’ll be penetrating the roof, so the roof structure must always be inspected.”
Other installers note that it’s generally better (if possible) to mount channel letters below the roofline.
Another survey checklist item is the building façade color. Experienced installers will ask if that color will remain the same during the installation period.
A new sign will sometimes be a part of an entire building update—including the façade paint color. If that color is changing, the channel letter color configuration may also need to change.
Sign shops should also be certain the customer has consulted with the landlord as to which signage types are permissible.
“Nine times out of ten, the customer will not have checked with the landlord,” says Larry Plath of Southwest Outdoor Electric Signs in Albuquerque, New Mexico. “The customer will know what they want but not what they can have.”
In summary, a professional site survey encompasses more than just a quick “surface level” inspection. It requires a working knowledge of building construction and materials, electrical wiring configurations, and an on-site assessment of the necessary equipment and personnel.
Permitting and Building Inspection
Permitting is another important facet of the installation process. “We try to research the sign up front so we don’t quote a sign the customer is not permitted to have,” says Schultz. “In most cases, you must have landlord approval to go after a permit. Then we always obtain the actual permit prior to fabrication.”
Schultz also points out that many municipalities and cities now allow permit materials to be submitted online, which can save a trip to their office.
One interesting point: Experienced installers usually keep a hard copy of the permit(s) available at the installation site. A building inspector may show up and ask to see a hard copy.
Construction and Mounting Surfaces
For channel letter installations, some wall materials are more difficult to work with than others.
Concrete can be more difficult to drill and is also more time (and labor) intensive. (Note: Several installers cite concrete as a troublesome material.)
Along the same lines, an additional potential issue is a wall that appears to be stucco on the surface but actually has a concrete wall behind it.
Stucco itself can actually cause problems, as some surfaces that appear to be stucco are not actually flat—they’re slightly corrugated. This isn’t always perceptible when the building facade is viewed from a distance and can impact the appearance of mounted letters (particularly halo-lit letters.)
Corrugated metal can be another problematic surface. Outside of the potential mounting stability issue, a corrugated surface can also throw off the halo appearance of a reverse-lit letter set.
Of course this is more of a guideline than a rule.
Curry mentions an installation that specified reverse-lit letters on a corrugated mounting surface. They warned the customer that the halo appearance wouldn’t be ideal, but the customer insisted on reverse-lit letters and was actually pleased with the result.
EIFS is sometimes called “synthetic stucco,” but it is not stucco. EIFS (“exterior insulation and finishing system”) is a building cladding material that provides exterior walls with an insulated, water-resistant finished surface.
It is also another potentially challenging building material, as it doesn’t always provide a firm backing and can present other issues as well.
“We once ran into a situation where the letter set to be replaced had been siliconed to the wall. When we removed those letters, we tore off chunks of EIFS foam,” says Schultz. “We had to explain to an out-of-state company why the wall was so torn up. That foam can be six inches thick.”
A double wall can prove another installation issue. Schultz mentions that his company once had to mount letters where the two combined walls were thirty-six inches thick and had a small void between them. A specialty drill bit was utilized to penetrate the unusually large distance.
Ceramic wall tiles may also present a mounting problem. These tiles may shatter if the wrong drill bit is used. A specialty bit is often required.
“You never really know which bits will work best with different types of tile,” says Schultz. “Carbide pointed bits sometimes work well to prevent shattering.”
These are just a few of the potential construction and material challenges associated with a channel letter sign installation. Again knowledge and experience are necessary.
Installation Personnel
The customer [and even the sign shop] should protect their channel letter investment by making sure to hire an experienced and competent installer.
The number of installation personnel varies depending on the channel letter sign’s size and weight and the sign’s final location. The crew also depends on the installer’s experience level.
Some installers are able to complete a letter set installation alone. However, if help is needed, they’ll typically hire a licensed contractor who carries their own liability insurance.
Other companies generally employ a two-person installation crew, but they’ll subdivide their install crews by experience level.
Electrical Access and Connection
All installers agreed electrical access is a critical issue—especially when there is a lack of access and a wall either has to be opened up and/or secondary wires must be pulled.
Still licensed electricians don’t always have to be called in.
“It depends on the situation,” says Blumenfeld. “Our company is licensed to hook up electrical, if the power run is within ten feet of the sign. If the run is longer than ten feet, we’ll use an electrician to do it.”
Some states require a licensed electrician to inspect and/or connect the wiring prior to the sign being placed into operation. Experienced installers should always check the electrical permit law and sign codes in the installation’s jurisdiction.
“We bring in an electrician not only for their expertise but also to head off problems from the outset,” says Curry. “The customer pays a bit more, but it gives both us and [them] peace of mind.”
Mounting Pattern
An installation mounting pattern is typically supplied by the letter producer (assuming the letters are flush-mounted; raceway mounted channel letters typically don’t receive a mounting pattern). This document provides mounting data including the electrical knockout and mounting hole locations (see diagram).
Some companies utilize not only the mounting pattern but also other visual project documentation.
“We use the pattern, “ says Blumenfeld, “and we also print out the project visuals we’ve produced for the customer.”
Some installers also produce channel letters and have the ability to make their own mounting pattern when necessary.
“We’ve made our own patterns and had patterns supplied from manufacturers,” says Plath. “Installations are easier with a pattern, and we’ve generally found it’s less expensive to order from a manufacturer.”
By John Baylis, marketing director at Direct Sign Wholesale in Denver, Colorado.
Photos (top to bottom): Frohling Sign Company in Nanuet, NY; Direct Sign Wholesale.
