How to Reduce the Risk of Aluminum Wiring
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How to reduce the risks associated with aluminum electrical wiring
Aluminum wire repair method details and aluminum wire repair products are described here
Aluminum to copper pigtailing & aluminum to aluminum wire splices are here
This website answers nearly all questions about aluminum wiring inspection, hazards, repairs
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This article summarizes the immediate safety steps needed in a building where solid conductor aluminum electrical wiring is installed. This article describes the acceptable methods to repair aluminum wiring, including which aluminum wire connectors to use for safest results.
Photos above show an infra-red photo of an overheating aluminum wiring
connection at an improper aluminum-to-copper "pigtail" splice (courtesy of G. Cohen). Aluminum wire connections can overheat enough to
start a fire without ever drawing enough current to trip a circuit breaker, and improper repairs can increase the hazard.
HOW TO REDUCE THE RISK of Fire and Electrical Circuit Connector Overheating in buildings with Aluminum Electrical Wiring
Immediate Actions for Safety of Aluminum Wiring
See if you have aluminum wiring (solid conductor branch circuit) installed in your home. Aluminum wiring identification tips are
provided at ALUMINUM WIRING, HOW TO RECOGNIZE
Look for signs of aluminum wiring failure, such as flickering lights, turn off the circuit involved and call a licensed electrician. See U.S. CPSC 516 (linked-to below) for other trouble signs.
Install smoke detectors at locations recommended by your local building officials or fire department. Sample smoke detector locations are also provided on instructions that come with the smoke detector.
How to Repair Aluminum Electrical Wiring to Reduce the Hazards - Repair Alternatives & Choices
Once the initial steps above have been addressed here are the choices for safe repair of aluminum wiring:
Aluminum Wiring Repair Method No. 1: Re-wire the Building, Replacing All Aluminum with Copper Wire
Re-wire the Building replacing all aluminum branch circuit wiring with copper, as a "best repair method" for aluminum wiring, OR as a
next-best aluminum wiring repair method
Aluminum Wiring Repair Method No. 2: Copper Pigtailing using the COPALUM Connector
COPALUM Copper-to-Aluminum Pigtailing Use the special AMP (now TYCO) COPALUM connector and special tool to
connect short copper wires to every aluminum wire end in the Building, reconnecting the copper to the
various devices (outlets, switches, lights) and splices.
This "copper pigtailing" procedure is performed by an electrician trained
and licensed by AMP or TYCO to use this COPALUM procedure.
The TYCO COPALUM connector method is described
is described at PIGTAILING USING AMP "COPALUM" CONNECTORS.
Typically this approach costs about half that of completely re-wiring a home with copper.
TYCO currently leases the crimp tool necessary for making COPALUM repairs, and training is needed to use it properly. For photos of the TYCO COPALUM "Retermination Kit" - the crimping tool used to install COPALUM connectors on aluminum wiring, see this TYCO COPALUM Tool document. (PDF)
You'll see that the tool is large, making work in tight quarters a challenge, especially if the original lengths of wire to be pigtailed are short.
You'll also read in Tyco's draft contract for electricians that TYCO considers "old technology" aluminum wire to be unsafe, but in fact later-installed "new technology wire" performs about the same. Both "old technology" and "new technology" solid conductor aluminum wire alloys varied from manufacturer to manufacturer, some performing better or worse than others.
How to Become a Certified COPALUM Installer for Aluminum Wiring Repairs
The following material is based on information from Tyco Electronics, supplier of the COPALUM connector and crimping tool used for aluminum wiring repair:
Becoming a Certified COPALUM Installer - Certification Procedure
Review, sign and return the contract for the COPALUM Retermination Program.*
Contact a participating local Electrical Distributor for availability and delivery of the COPALUM Retermination Tool.
Contact Tyco Electronics to set up a training date for certification training.
Certification Card is provided after completion of training for the purchase of product.
Pricing and availability only through a participating Electrical Distributor
Tooling: Lease only option (Tool is NOT available for sale)
3 month minimum lease — Contact a participating Electrical Distributor for pricing.
Monthly Fee — Contact Electrical Distributor for pricing.
Certification Training is provided by Tyco Electronics Field Service Specialist.
Training consists of 2 to 4 hour instruction for tool use & connector application.
Training Cost - $ 750.00 plus travel & expense (Limited to 6 participants).
Once contractor has tool availability date from distributor, contact Tyco Electronics to schedule training date.
Contact Tyco Electronics customer service for additional information at 800.468.2023.
Contractors can identify distributors in their area by contacting 1-800-527-6686.
see Tyco Electronics for details about COPALUM certification, crimping tool leasing, supplies, training. Terms and conditions of leasing the COPALUM retermination tool (crimping tool) for aluminum wire repairs includes requiring that the contractor be properly trained in use of the equipment.
The Tyco part number for the Tyco COPALUM retermination tool (crimping tool) is 1976330-1.
The Tyco part numbers for the COPALUM crimp connector itself are 608501-1(Red) & 608502-1(Blue) (two sizes).
Currently only these two remedies above have been formally recommended by the CPSC. Other aluminum wiring repair connector products
have been sold by various manufacturers, some with good performance and some unacceptable. Descriptions are below. Emergency temporary
repairs necessary to keep an essential circuit in service might be possible following other procedures described by the CPSC or by industry experts.
Current Shortcomings of the COPALUM Aluminum Wiring Repair Method - Economics
OPINION: Problem for Large Electrical Contractors repairing aluminum wiring: Tyco should make the COPALUM crimping tool available for sale: Unfortunately, Tyco's "rent-only" option for the COPALUM connector makes aluminum wiring repair service prohibitively expensive for large electrical repair companies who are performing extensive aluminum repair work in large urban areas.
Placing multiple repair tools in multiple repair service trucks with aluminum-wire repair-trained experts, and keeping them there year in and year out in order to be responsive to consumer needs prices this service right out of that market place and has tempted some aluminum repair electricians to make use of alternative repair methods that appear to work (the AlumiConn discussed below) and other aluminum repair methods that have been shown to be ineffective and dangerous.
OPINION: Problem for Small Electrical Contractors repairing aluminum wiring:Tyco should make the COPALUM crimping tool available for short term rental: A small electrical contractor wanting to become trained, certified, and qualified to perform a small number of aluminum wire repairs faces a different problem. Tyco rents the COPALUM crimping tool for a three-month minimum, converting to a month-to-month lease thereafter. This will not be economical for a small contractor performing only occasional aluminum wiring repairs.
Aluminum Wiring Repair Methods - Alternatives Under Consideration
AlumiConn TMaluminum to copper lug connectors[New in 2006, U.L. Listed, 2007 completed independent testing]
available from King Innovation. Results of independent
testing indicate that this product "... is predicted to have a high probability of failure-free long-term safe performance,
PROVIDED THAT THE SETSCREWS ARE CAREFULLY TIGHTENED TO THE MANUFACTURER'S RECOMMENDATION".
Reference: details of the study and recommendations are on page #6 (the 9th page in the .pdf file) in Dr. J.A. Aronstein's .pdf document version of
"Reducing the Fire Hazards in Aluminum Wired Homes" May 21, 2007.
The test results are completed and will be published in September 2007.
(100 connectors cost $285. Lower prices for larger quantities.) At MAKING SPACE FOR ALUMINUM WIRE CONNECTORS we discuss options for fitting the AlumiConn™ connector and pigtail wires into electrical boxes where space is tight.
Technical note on binding and poor wire connections in aluminum terminal blocks:
In larger-sized electrical wire connector applications such as electrical panel buses (not this product),
we have seen aluminum-block connection
failures occur when the steel screw bound in the aluminum block,
appearing to be a tight connection before proper contact with the wire has been made.
Mr. King informs us that they have addressed this concern by plating the screws in nickel and plating the lug block in tin,
thus eliminating the galling found in other lugs. Also there is a very small gap at the back of the
wire terminal block where the installer can see the wire (coated in sealant) coming through. This
provides visual confirmation that the wires came all the way through.
Finally, King always recommends that installers to check the connection security by giving a quick tug on the
wires to make sure they are tight. This UL-listed connector has not been recommended, nor recommended against, by the US CPSC.
AlumiConnTM Status Update - Ready for Prime Time?
Question:
In the section regarding aluminum wiring repair it is not clear to me if the product called Alumiconn by King Innovation is a safe and acceptable alternative to Copalum. I have not been able to find anywhere in the internet any further references to how safe is this product beyond the publication by J. Aronstein last update July 6, 2007. Can you clarify this for me?
- J. C., Orlando, FL
Answer: Safety/Usability of the Alumiconn: Five Points of Discussion
1. Independent tests showed that IF the Alumiconn connector is properly installed (including torquing to the proper torque setting) it performs as well as COPALUM. We have absolute confidence in Dr. Aronstein in this matter - he is fully qualified, experienced, and is an unbiased independent party with no financial connection to the company selling Aluminconn (nor to any one else selling other products).
The Alumiconn™ is UL listed (UL 486C) as a "pressure type screw connector" (USA) and CSA approved (Canada) for aluminum wiring repairs.
For general information about that listing type, see this UL connector information on the UL listing for wire connectors.
But:
2. U.S. CPSC: My understanding is that the Alumiconn has not yet been added by the US CPSC to their recommended repair methods.
3. Torque: Reading the UL document we see no mention whatsoever of torque specifications - those are particularly important for this particular connector as it involves tightening a screw in a terminal block to secure the aluminum or copper wire being spliced. Aronstein emphasized that the connector's acceptable performance relied on using the proper torque settings.
Torque settings are at the AlumiConn site - you'd need the $100. SK torque screwdriver to install these connectors - costly, but much less so than renting the COPALUM crimping tool and becoming certified to use it.
The "alternative method" described by the manufacturer for tightening the screws produces torque close to or exceeding the actual torque specified numbers (according to some preliminary tests we have done in our lab) - photo at left.
But we are not confident that that approach would be adequate for general field use where human performance may vary considerably.
4. UL listing vs CPSC Recommended: So if you were working for someone else and wanted to install only the CPSC-recommended connectors, you'd use only the AMP/TYCO COPALUM method until we hear newly from the CPSC on the Alumiconn.
In March 2010 we (DJF) presented this information for a group of 50 licensed electricians at an Aluminum Wiring Repair Methods Update - class in Dallas TX. These were trained licensed electricians who are informed and conservative in their practice. The company's position was that they won't use the Alumconn until it's CPSC-recommended, notwithstanding its UL listing. We respect that position. After all, products carrying a UL listing for aluminum wiring repair have been shown to perform very poorly in the field, such as
CU/AL devices and the Ideal65 purple "Twister" connector sold for that purpose.
5. We anticipate that the AlumiConn will be CPSC recommended soon - but then, we have heard that since 2009 and we are still waiting.
How to Repair Aluminum-to-Aluminum Wire Connections in buildings
Aluminum to aluminum wire splices also need to be repaired in an aluminum-wired home. The various "copper pigtailing" methods
discussed in articles on aluminum wire repairs (at aluminum-wired devices such as electrical receptacles, switches, and lights)
are not the best approach when repairing aluminum-to-aluminum wire splices such as at a
junction box in a building (where several aluminum-wire circuits or wires are joined together).
[DF note: For the aluminum wire to aluminum wire connector case, use of a splicing connector whose manufacturer specifies that the connector must be used with a combination of copper and aluminum wires together makes little sense.
Our photograph at above left shows aluminum wire spliced to aluminum wire at a connection which had not overheated when we took this photo. The photograph at above right shows severe overheating and burn-up of an aluminum to copper splice made using a conventional twist-on connector. ]
For the small aluminum wire sizes such as found in building branch circuit wiring for lighting and receptacles, the AlumiConnTM is probably the best choice if the COPALUM connectors and special crimping tool are not readily available.
For larger aluminum wire sizes sizes (stranded aluminum wiring such as found at air conditioning compressor circuits, electric
range circuits, clothes dryer circuits and other high-amp devices), any of the (UL listed for Aluminum) setscrew type connectors
in combination with the inhibitor/abrasion installation technique should suffice.
Since we've seen frequent field reports of overheating at multi-strand high-amp aluminum wired devices such as air conditioning compressors, it is important
to address these cases by proper repair methods. [Note: some air conditioning equipment manufacturers currently recommend use of only
copper wiring to feed their equipment - DJF June 2007]
Other Approaches to the Repair of Aluminum Electrical Wiring
Scotchlok 3M Special Method [- superceded by new alternate repair as of June 2007 -]: this ""Scotchlok 3M Special Method was previously recommended as independent tests showed that it performed acceptably.
While this repair method has been superceded by new alternate repair as of June 2007, we have kept this description available to aid home buyers, electricians and home inspectors
who may discover or need to be able to recognize this aluminum wire repair method if it was previously used in the building. A summary of this method is at
"Scotchlok 3M connector" and details of this method are
at Aluminum Wire alternative repair: Special Aluminum Wire Repair Method
Other methods - not recommended: Warnings regarding other "repair" methods which are not recommended
are discussed at ALUMINUM WIRING REPAIR, Other Products, such as the
Ideal 65 purple "Twister" aluminum wire splice connector shown in the photo at left (12 connectors cost $49. to $79.)
Other methods - also not recommended: include attempts to repair aluminum wiring using
receptacles and outlets marked "COALR" (even if these worked, which has not been
demonstrated, what about all of the other electrical connections and splices in the building?). COALR and CU/AL devices
as a "repair" for aluminum wiring is discussed at ALUMINUM WIRING REPAIR, Other Products.
Reducing the Fire Hazards in Aluminum-Wired Homes - 2007 Update, [large .pdf document], Jess Aronstein, Ph.D., 21 May 2007. This document answers most technical questions about the hazards and remedies of aluminum electrical wiring and includes
a report on independent test results of alternative products and methods for repairing aluminum wiring.
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Dr. Jess Aronstein, protune@aol.com is a research consultant and an electrical engineer in Poughkeepsie, NY. Dr. Aronstein provides forensic engineering services and independent laboratory testing for various agencies. Dr. Aronstein has published widely on and has designed and conducted tests on aluminum wiring failures, Federal Pacific Stab-Lok electrical equipment, and numerous electrical products and hazards. see Aluminum Wiring Bibliography and see FPE HAZARD ARTICLES, STUDIES for examples.
"The Influence of Corrosion Inhibitor and Surface Abrasion on the Failure of Aluminum-Wired Twist-on Connections",
Aronstein, J.; Campbell, W.,
Components, Hybrids, and Manufacturing Technology, IEEE Transactions on
Volume 7, Issue 1, Mar 1984 Page(s): 20 - 24
"Aluminum Wiring: Understanding the Problem and Its Solutions", Hartford Insurance Company - NOTICE: this information contains technical errors and some obsolete information. We include the document reference as an indication of insurance companies who are aware of aluminum electrical wiring hazards and costs. Local copy.
WANTED: Aluminum Wiring Field Reports, Photographs, Samples, & Failure Cases & Data for ongoing study on frequency and severity of occurrence of problems.
If you have experienced any problem, or symptom of possible problem with aluminum electrical wiring, or have repaired or replaced it, please contact Daniel Friedman. All information is confidential.
Study results will be provided to the U.S. Consumer Product
Safety Commission and to the electrical industry. Real life aluminum wiring field failure reports can be seen at Aluminum Wiring Failures in Residential Properties: Field Reports & Pictures.
Books & Articles on Building & Environmental Inspection, Testing, Diagnosis, & Repair
Our recommended books about building & mechanical systems design, inspection, problem diagnosis, and repair, and about indoor environment and IAQ testing, diagnosis, and cleanup are at the InspectAPedia Bookstore. Also see our Book Reviews - InspectAPedia.
Recommended books on electrical inspection, electrical wiring, electrical problem diagnosis, and electrical repair can be found in the Electrical Books section of the InspectAPedia Bookstore. (courtesy of Amazon.com)
How to Reduce the Risk in buildings with Aluminum Electrical Wiring - Overview of Acceptable Repair Practices (in the document you are presently viewing)
Aluminum Electrical Repair Method Details - "How to" details, how to identify, COPALUM repair, alternative repairs, history, products, research, source of special AMP TYCO COPALUM connectors & COPALUM Electricians (in the document you are presently viewing)
COPALUM Electricians: Sources of TYCO COPALUM -Certified/Trained Aluminum Wire Repair Services (in the document you are presently viewing)
05/21/2007 Reducing the Fire Hazards in Aluminum-Wired Homes, [.pdf document], Jess Aronstein, Ph.D., 21 May 2007. This document answers most technical questions about the hazards and remedies of aluminum electrical wiring and includes
a report on independent test results of alternative products and methods for repairing aluminum wiring. Some of the sections of this very thorough document are listed below:
02/09/2006Reducing the Fire Hazards in Aluminum-Wired Homes, Jess Aronstein, Ph.D., This older version of the above document also answers most technical questions about the hazards and remedies of aluminum electrical wiring
but lacks latest repair product testing such as the AlumiConn connector discussed above. Some of the sections of this very thorough document are listed below:
[UPDATED-DF 03/08/2003, Edits-df 02/09/2006]
Pigtailing using COPALUM - CPSC recommended,
Pigtailing using Scotchlok 3M - superceded by new alternate repair as of June 2007 - a tested, useable aluminum wiring connector method, with a link to step-by-step "how to" photos,
Pigtailing using Ideal 65 - NOT RECOMMENDED, aluminum wiring failures research, field and lab experience, expert sources.
Circuit Breaker, a bad one fails to trip failure at aluminum bus-to-circuit breaker connection - field report and photographs
Electrical Panels, How to Inspect in buildings, safety for electrical inspectors, electrical panel, fusing, wiring defects, defective products. Inspection Class Presentation
Mobile View
Other methods - not recommended:
The Aluminum Wiring Information Website 
Carson Dunlop's Home Inspector's Home Study Course