Aluminum Electrical Wiring Hazard Summary
Aluminum Wiring in Residential Properties: Hazards & Remedies
This page presents a summary of information provided at the Aluminum Wiring Information Website hosted at the online encyclopedia InspectAPedia.com. That website contains more extensive information for consumers and building professionals regarding aluminum electrical wiring in residential properties. Actual documents, authoritative research, and government resources about aluminum wiring are found there. That website is the most extensive and authoritative Internet information source for aluminum wiring and related hazards. [This page may be freely distributed in print or electronic form and may be copied to other websites. Do not alter the content of this page without first contacting us for permission. InspectAPedia.com privacy and content use policies can be viewed at Accuracy & Privacy Policies.]
The Hazard
Aluminum electrical wiring, used in some homes from the mid 1960's to the early
1970's, is a potential fire hazard. According to the U.S. Consumer
Product Safety Commission, fires and even deaths have been reported to
have been caused by this hazard. Problems due to expansion can cause
overheating at connections between the wire and devices (switches and
outlets) or at splices. CPSC research shows that "homes wired with
aluminum wire manufactured before 1972 are 55 times more likely to have
one or more connections reach "Fire Hazard Conditions" than are homes
wired with copper. "Post 1972" aluminum wire is also a concern.
Introduction of the aluminum wire "alloys" in 1972 time frame did not
solve most of the connection failure problems. Aluminum wiring is still
permitted and used for certain applications, including residential
service entrance wiring and single-purpose higher amperage circuits
such as 240V air conditioning or electric range circuits.
Reducing Risk
As of the current date of this page, only two remedies have been recommended by the CPSC:
- Discontinued use of the aluminum circuit or,
- Pigtailing: less costly, the addition of copper connecting
"pigtail" wires between the aluminum wire and the wired device
(receptacle, switch, or other device). The pigtail connection must be
made using
- The COPALUM connector, a special connector and special crimping tool licensed by the AMP Corporation.
- The AlumiConn TM aluminum 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".
- A special installation method was previously described using special procedures but this method is now considered obsolete given the two options and products listed above
- Emergency temporary repairs necessary to keep an essential circuit in service might be possible following other procedures described by the CPSC.
WANTED: Aluminum Wiring 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 at InspectAPedia.com using this Contact Us link. All information is confidential. Study results will be provided to the U.S. Consumer Product Safety Commission and to the electrical industry.
More Information
- Aluminum Wiring Information Website - the aluminum wiring home page
- FPE Stab-Lok HAZARDS & REPAIRS WEBSITE - the Federal Pacific Electric FPE Stab Lok latent hazard public information website
- Recognizing Aluminum Wiring photos and tips on how to recognize aluminum electrical wiring in buildings
- Reducing the Fire Hazards in Aluminum-Wired Homes, methods, research, experience, expert sources. This document answers most technical questions about the hazards and remedies of aluminum electrical wiring. UPDATED 3/5/2003
- Fire Hazards With Aluminum to Copper Twist-on Connectors & Acceptable Repair Practices Color Photos, Alternative Retrofit/Repair Procedures, Current Issues. 9/28/95 CPSC Meeting Minutes
- "Is YOUR Aluminum Wiring Safe?" article discussing safety claims made without looking at the wiring, J. Aronstein, 11/21/95
- "Repairing Aluminum Wiring," Consumer Product Safety Commission Booklet CPSC#516
- AMP COPALUM CONNECTOR - this one works
- 1 May 2003 - U.S. CPSC announced that Tyco Electronics Corp. will continue offering the COPALUM connector repair system until at least 2005 - for details see the Tyco Press Release.
- AMP Corporation, Harrisburg PA 17105 800-522-6752 - CPSC's recommended COPALUM aluminum-copper retrofit - US Customer Support 800-522-6752 [See the TYCO announcement above]
- AMP Canada Product Information Department, 905-470-4425 the COPALUM connector line is available in Canada; they do not appear to have a contractor training/certification program such as is (at least in a few places) available in the USA.
- AMP COPALUM Connectors & Equipment Source for at Tyco Electronics
- AlumiConn™ is a website with information on obtaining the AlumiConn™ aluminum wiring connector.
- Certified, Experienced Electricians Offering Aluminum Wire Repair Services
- See this list of Electricians Experienced in Aluminum Wiring Repairs
-
Ideal-65 Twister - this one doesn't work - purple twist-on connector sold for aluminum wire repair - CPSC reiterates unsuitability of twist-on connectors (Including the Ideal No. 65) for repairing aluminum wiring in residences.
- Independent Tests indicate Ideal-65 Twist-on retrofit connector fails UL 486C Safety Standard despite UL-listing
- Ideal 65 "Twister" History of and Links to CPSC Documents about Purple Twist-on connector failures
- Ideal Industries, Inc., 1000 Park Ave, Sycamore IL 60178-9946. 800-435-0705 U.S. or 800-527-9105 Canada. ideal@wirenut.com
- J. Aronstein, "Evaluation of a Twist-on Connector for Aluminum Wire", Forty-Third IEEE Holm Conference on Electrical Contacts, Jan 1997, 0-7803-3968-1/97.
[This article describes the Ideal Industries Ideal#65 purple "Twister" twist-on connector marketed as a repair/retrofit for residential aluminum wiring.--DJF]
Abstract: A new type of twist-on splicing component for use with aluminum and copper wire combinations is tested to determine initial resistance, performance in a zero-current environment test, performance in a heat-cycle test, and portion of current carried by the connector's steel spring. The splices tested consist of two aluminum wires and one copper wire. The aluminum wire samples used for the test are of the types actually installed in aluminum-wired homes. Initial resistance is found to be relatively high, and there is a significant sample-to-sample variation. This reflects failure to consistently establish low-resistance wire-to-wire contact through the insulating oxide film on the wire. Results of the environmental and heat-cycle tests show deterioration of a significant portion of the samples. The splices made with this connector are also found to be sensitive to mechanical disturbance, such as applied in normal installation when the completed splice is pushed back in to the junction box. Based on the test results, it is concluded that this connector has not overcome the fundamental deficiency of twist-on connectors for use with aluminum wire applications. Keywords: aluminum wire, connectors, twist-on connectors, environmental test, heat-cycle test.
- Southwire Corporation, manufacturer of aluminum (and other) wire products
- Bibliography: resources on Aluminum Wiring
- ZINSCO / SYLVANIA HAZARDS - field reports indicate no-trip problems and circuit breaker case explosions with this product;
- FAQs on InspectAPedia.com author/website credibility
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