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This article describes a working alternative repair method for aluminum wiring [- Superceded by new alternate repair as of June 2007] but documented here as an aid to recognizing the occurrence of this repair method in existing installations.

In this aluminum wiring repair method, in which copper pigtails were spliced to the aluminum wire ends using a specific twist-on connector, antioxidant, abrading, and pre-twisting of the wires. Independent testing of this method indicated that provided the work was performed correctly these splices performed well and could significantly reduce the risk of aluminum-wire caused fires in buildings.

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The availability of the AlumiConn beginning in July 2007, a UL listed connector intended for this repair and which was tested successfully, resulted in our statement that the alternative method described here has been supersceded by a new alternative repair.

we have maintained this [now obsolete] repair description to aid in recognition of this repair in buildings where it may have been applied.

This repair was considered appropriate for cases where the AMP TYCO COPLAUM connector method and electricians trained to use that method were not available.

This is Aluminum Wiring Repair Procedure - Page 12 Color photos and descriptive captions from a CPSC Meeting held on 9/28/95. This presentation describes an alternative repair method for aluminum wiring which was at that time considered useful where the AMP TYCO COPALUM special connector and electricians trained to use it were not available.

This alternative repair for aluminum electrical wiring used readily-available components. It was tested and found reliable when performed by a properly trained licensed electrician or similarly qualified expert. As with any electrical wiring repair, but perhaps even more important in this case where the starting point is unsafe aluminum electrical wiring, it was essential that the repair procedure was correctly performed.

This document presents color photos and descriptive captions from the CPSC Meeting on 9/28/95 where this aluminum wiring repair method was described. 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 US CPSC minutes were obtained under the Freedom of Information Act and posted by Daniel Friedman January 1996, updated June 2007 to reflect the availability of a new alternative to the COPALUM, the AlumiConn, and noting that the use of the Scotchlok 3-M method described here is - superceded by new alternate repair as of June 2007.

Special Aluminum Wire Repair Method For Use When the COPALUM Method is Not Available - Page 1 of 2

For in-depth discussion of the procedures described below also see Reducing the Fire Hazard in Aluminum-Wired Homes by Dr. Jesse Aronstein.

Click any image to see an enlarged versin.

35. Unfortunately, however, the COPALUM repair is not readily available in some areas of the country, and is impractical if there is only need to connect a single fixture or appliance. Some twist-on connectors may work well as an alternative, providing that they are installed in a special manner - superceded by new alternate repair as of June 2007.


36. The special installation method described here - superceded by new alternate repair as of June 2007 - is based on industry (Ideal, GE, Etc) recommended practice considered to be necessary for proper connection to aluminum. The wires are stripped over length, and a coating of oxide inhibitor is applied.



37. The inhibitor used should be one that does not ignite and flame readily. Such compounds are commercially available. "Penetrox A," shown here, is one of them.

Orrey W. Hiebert was kind enough to suggest another inhibitor: Burndy Pentrox A which he says does not ignite. These compounds are available from most electrical wholesale suppliers. A contemporary version of De-Ox by Ilsco, a gel that comes in a white squeeze bottle, is reported by some of our readers to no longer support combustion. [Email from G.S to DJF 11/16/06)].

38. Other brands, including the one, NOALOX(TM) made by Ideal and used in their #65 connector, ignite readily and burn vigorously.



39. The aluminum wire is abraded under the coating of oxide inhibitor, using, for instance, #220 grit automotive wet-dry finishing sandpaper. This is an important step. Abrasion disrupts and removes much of the insulating oxide, and the inhibitor film prevents fresh oxide formation on the bare aluminum. Scroll Down to Rest of This Page



40. The wires to be spliced are held together and gripped in the jaws of a pair of pliers.

41. The wires are twisted together tightly, using the pliers. This is called "pre twisting."

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Aluminum Wiring Repair Methods - CPSC Meeting 9/28/95
  Contents
  Copper Pigtailing
  Pigtailing failures
  Additional failures
  Field Failures
  Wire-to-wire Contact
  Equivalent Circuits
  Current Flow
  Connection Deterioration
  UL Test Inadequate
  "Special Connector" Failures
  AMP TYCO COPALUM
  Alternative Repair
  Special Concerns

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.
• The Aluminum Wiring Information Website Aluminum Wiring Hazards and Repairs: in-depth info, photos, documents. Main Page.
• The Aluminum Electrical Wiring Hazard Explained (in the document you are presently viewing)
• 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)
• Other Products, Ideal 65 Purple Twister (not recommended), & other Aluminum Wire Products/Articles (in the document you are presently viewing)
• The Aluminum Wiring Bibliography: extensive resources on Aluminum Wiring
• Aluminum Wire Failure Reports & Photos: Real life aluminum wiring field failure reports
• 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:
• Fire Hazards With Aluminum to Copper Twist-on Connectors & Acceptable Aluminum Wiring Repair Practices Color Photos, Current Issues. 9/28/95 CPSC Meeting Minutes
• "Is YOUR Aluminum Wiring Safe?" article discussing safety claims made by some people without looking at the wiring, J. Aronstein, 11/21/95
• "Repairing Aluminum Wiring," U.S. Consumer Product Safety Commission Publication CPSC#516 available online
• * Safety Hazards and Safe Inspection Procedures for Electrical and Home Inspectors at Residential Electric Panels
• Electrical Panels, How to Inspect in buildings, safety for electrical inspectors, electrical panel, fusing, wiring defects, defective products. Inspection Class Presentation
• Electrical System & Wiring Hazard Inspection, Detection, Cause, Remedy, Prevention - Main Electrical Page
• Directory of Home Inspectors accessible via Internet
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