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This page discusses special problems with the combustibility of antioxidant and plastic used in the Ideal 65 Twist-on purple "twister" connector if used for splicing aluminum to copper wires.

This is Aluminum Wiring Repair Procedure - Page 13 Color photos and descriptive captions from 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 describes hazards with existing 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.

Click on the thumbnail sketches below to see each full-sized illustration.

50. Installed per the manufacturer's instructions, many in retrofit installations, hazardous failures will occur in considerable numbers over the years. The free-burning connector shell is then a cause for concern. A substantial fire can grow from ignition of a connector shell, as shown in this demonstration.


51. The only materials here are those intended to be in the box: the wires, a connector, and the end of the cable sheath. A failing aluminum twist-on splice can ignite its own shell. In this demonstration the connector shell was ignited by a match. A burning glob of plastic drips to the floor of the metal box,

52. The flame does not extinguish. Interaction between the shell and the dripped plastic keeps it going. In an actual installation the side and front of the box would be enclosed, but there are generally enough openings and gaps to provide sufficient air for combustion.



53. The temperature of the wire insulation has increased to the point where it too will burn, and the fire grows.




54. At this point the connector is completely burned out but the fire continues on the wire insulation and cable jacket end. In the wall of an actual home, the fire may spread or not, depending on details. Clearly, however, the inside of the electrical box is no place for free-burning material.
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55. The Ideal #65 connector has more free burning material than the connector shown in the previous demonstration, because it is filled with highly-combustible inhibitor. Now, imagine an outlet box with two or three of them. That is quite a fire lighter.

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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

More Information on Building Diagnostic Inspections and Repairs

• 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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