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This article contains photo-documented reports of actual in-service aluminum wiring failures in homes. I have been receiving reports from home owners, builders, and building professionals since 1990. However this page was created in July 2004, so it will not contain all of the historical data.

Recent reports, photographs, anecdotes will be displayed here. When I complete statistical analysis of prior reports I'll add that data at this page. Readers should also see the Aluminum Wiring Website home page.

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Aluminum Wiring Overheating Reports with failure photographs

240V Heat Pump Circuit - Aluminum Wiring Failure Case

Whoever wired the previous unit must have had some Al wire around but not quite enough to reach the unit, so they used a junction box to connect Al and Cu wire. Fortunately, the so-called technicians used a steel box otherwise the house could have burned down. This was the only aluminum wiring I have found thus far but I'm not done inspecting yet."-- J.F. 6/30/2004 DF-note: see also this lab photograph of an overheating twist-on connector to show the overheat mechanism in the case above

Ideal-65 "Twister" Burnup in Field Use - Aluminum Wiring Failure Case Photos

Electrical Panel Overheat - Aluminum Wiring Failure Case Photos

Electrical Receptacle Burnup - Aluminum Wiring Failure Case Photos

Copper to Aluminum Pigtail Overheat - in Electric Panel, including infra-red Case Photos

Contributor - Gordon Cohen: These thermal imaging photos of overheating aluminum splices and circuit breakers with aluminum wiring are courtesy of Gordon Cohen, June 2006. Mr. Gordon offers home inspections and thermal imaging services in Florida and is also employed by ServiceMaster as a project manager. Email: Infraredinspections@cfl.rr.com

Twist-on connector overheating cases - Forensic Engineer Reports

• Aronstein reports and provides these additional examples of aluminum wiring field failures.
  

Questions & Answers regarding this article

Questions & answers about aluminum electrical wiring field failure reports.

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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
• ...