Aluminum Wiring in Residential Properties: Hazards & Remedies
This website contains extensive information for consumers and building professionals regarding aluminum electrical wiring in residential properties. The contents are the result of study of this topic and represent the opinion of the author. Actual documents, authoritative research, and government resources about aluminum wiring are here. This is the most extensive and authoritative Internet information source for aluminum wiring and related hazards.

The Hazard

Aluminum wiring, used in some homes from the mid 1960's to the early 1970's, is a potental 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, 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 only a special connector and special crimping tool licensed by the AMP Corporation. Emergency temporary repairs necessary to keep an essential circuit in service might be possible following other procedures described by the CPSC. A special installation method is described in the article we posted on 1/31/96 below.

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 Dan Friedman using the contact information at the end of this page. All information is confidential. Study results will be provided to the U.S. Consumer Product Safety Commission and to the electrical industry.

More Information

• Recognizing Aluminum Wiring photos and tips
• 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
• AMP-Certified/Trained Aluminum Wire Repair Services
  • Colorado, Auroa - Aluminum Wire Repair, Inc., AMP-COPALUM certified, 720-299-4706 303-886-2850 Cell - contact Alex Costantino info@alwirerepair.com
  • Kentucky, Louisville - John Waters Corp AMP-COPALUM certified, 502-896-0850 or 502-896-8662 fax - contact Mike Bauerla mikeb@jwaters.com
  • Ohio, Cincinnati - Cooper Electric
  • Ohio, - Leitner Electric AMP-COPALUM certified
  • AMP-Certified Electricians: contact us to add your listing here IF you are a qualified aluminum wire repair service company or product provider.
• 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, peformance 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
• American Society of Home Inspectors, national professional association
• Bibliography: resources on Aluminum Wiring
• Consumer Product Safety Commission various information resources
• FAQs on author/website credibility
• The Free Construction Information Supersite

ASHI aluminum AMP Jess Aronstein burn electrical Ideal65 Twister fire hazards COALR COPALUM Code CPSC Consumer copper connector crimp Crimping Ideal 65 Products Safety Commission Dan Friedman melt lighting outlets pigtail Pig Tail purple receptacles repair rewiring re-wire retrofit safety twist-on Twister Underwriters Laboratories UL NFPA Aronstein wire nuts Wiring twist-on connectors home inspection Scarborough scarboro home inspection

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