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Using the COPALUM connector: this article describes the original aluminum wire repair method recommended by the US Consumer Product Safety Commission as an alternative to re-wiring, using the special AMP TYCO COPALUM high-torque crimp-on connector. This discussion
is followed (on the next page - page 12) by an alternative repair method for aluminum wiring which may be useful where the AMP COPALUM special connector and electricians trained to use it
are not available.
Procedures for Using the AMP/TYCO COPALUM Connector for Aluminum Wire REpairs, Evaluation, Comments, Details
This is Aluminum Wiring Repair Procedure - Page 11 Color photos and descriptive captions from CPSC Meeting 9/28/95. This document presents color photos and descriptive captions from aluminum wiring repair methods discussed at the CPSC Meeting 9/28/95.
In this document aluminum wire twist-on connector failures and repair procedures are described,including aluminum wire repair methods which work and methods which do not work and are unsafe.
Color photos of aluminum wire repair procedures, and photos of failed connectors are included.
This document series describes hazards with existing aluminum wiring repair products, explains the aluminum wiring failure mechanism,
and reviews recommended retrofit procedures including use of readily-available materials. This information was presented to the US Consumer Product Safety Commission by Dr. J. Aronstein, 9/28/95.
The minutes of that meeting were obtained under the Freedom of Information Act and posted by Daniel Friedman January 1996.
33. This connector, the AMP COPALUM, is the one recommended by the CPSC for the pigtailing application.
The connector is applied using special tooling and is only available with installation by
34. Here is an illustration of the pigtailing method using the COPALUM connector.
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Questions & answers or comments about using the AMP - TYCO COPALUM connector for aluminum wiring repairs.
Use the "Click to Show or Hide FAQs" link just above to see recently-posted questions, comments, replies, try the search box just below, or if you prefer, post a question or comment in the Comments box below and we will respond promptly.
 "Record of Commission Action, Commissioners Voting by Ballot", CPSC Publication No. 516, Repairing Aluminum Wiring (original version op.cit.), (Briefing package dated March 15, 2011), Quoting: The Commission voted unanimously (5-0)·to approve republication of CPSC Publication No. 516, Repairing Aluminum Wiring, with the explicit recognition that the COPALUM and AlumiConn connectors currently are the only products that meet the agency's standards to prevent aluminum wire fire hazards Copy on file as /aluminum/Pub516_Alumi_Conn.pdf
 Dr. Jess Aronstein, email@example.com is a research consultant and an electrical engineer in Schenectady, 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
 Thanks to reader Thomas Kremer
for suggesting clarification to this topic 08/09
 Personal communication, Email, P. King to D Friedman, 3/10/2012 [copy on file AlumiConn_PK120310.pdf].
Books & Articles on Building & Environmental Inspection, Testing, Diagnosis, & Repair
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ALUMINUM WIRE REPAIR METHODS to reduce risk in buildings with Aluminum Electrical Wiring - Overview of Acceptable Repair Practices (in the document you are presently viewing)
Aluminum Wire 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)
Other Products, Ideal 65 Purple Twister (not recommended), & other Aluminum Wire Products/Articles (in the document you are presently viewing)
Reducing the Fire Hazards in Aluminum-Wired Homes, Jess Aronstein, Ph.D., This document answers most technical questions about the hazards and remedies of aluminum electrical wiring. Some of the sections of this very thorough document are listed below: