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Aluminum Wiring by Douglas Hansen
Aluminum Wiring
by Douglas Hansen
Mention aluminum wiring and youll find a lot of folks who react as though youve said the house
has a voodoo curse. They may not understand why theyre supposed to be afraid of it, but they
suspect its one of those mysterious things youre supposed to run from. Im sure hoping that
there isnt some kind of bad ju-ju on aluminum wire, because thats what they use in airplanes. I
climb into an average of about three of those a week. Ill be in big trouble if that wiring doesnt
work, and Im not just referring to the darn blinking reading light.
How did aluminum get this reputation? Its actually been around for a very long time. We first
see it mentioned in the National Electrical Code in 1926, with an admonition that it isnt quite as
good a conductor as copper, though still much better than steel. Not much of it was used in the
old days. It was a fairly rare metal, and what use folks had for it was primarily in airplanes. After
WWII was over, we had finally geared up our aluminum production, and it was time for new
products. In 1964, Kaiser Aluminum (part of the Henry Kaiser empire he had been an
industrialist supplying liberty ships in WWII and launched many successful ventures thereafter)
produced the first aluminum nonmetallic sheathed cable. It was softer and easier to work with
than copper in some ways, but it did have to be one size larger because of the lower ampacity
of the wire. Soon enough, electricians all over the country were wiring houses with aluminum,
and connecting it just the same way they had done with good old copper.
Some of those wiring methods were all right, but a lot of them were suspicious. In the 1960s, it
wasnt uncommon to see houses wired with no wire nuts just twisted splices covered with
electrical tape, and to see barrel crimps used to connect a second wire to the middle of
another wire (figure 1). These connections are weak very poor by modern standards, and lots
of them fail, whether they are copper or aluminum. However, the situation got a lot worse with
aluminum when it was shoved into the quick-wire connections at the back of electrical devices.


Figure 1 - Arcing Barrel Crimp Connection with Copper Wire
The worst thing done with aluminum in those days was stuffing it into the quick-wire connections
at the back of receptacles. A simple way to make connections in a junction box with a
receptacle outlet is to feed through it, using the push-in connections in the back (figure 2).

Figure 2 Old Push-in Connections and Screw Terminal Connections
These push-in connections are bad enough with copper wire. About 10 years ago, UL changed
its standards to reduce the size of these holes so that only 14 gauge wire fits into them. That
way, they limit these connections to the 15 amp circuits. Of course, since aluminum wire is one
size bigger than copper for the same ampacity, that meant that aluminum couldnt be used at all
in these push-in connections. Nice idea, though it was 30 years late. Even before the reduction
in size of these holes, the device holes were marked as suitable for solid copper wiring only,
but back in the 60s there were no such markings. Electricians just hooked up aluminum wire
anywhere it would fit, doing exactly the same things they would do with copper wiring.
Such was the formula for the disasters of aluminum wiring from 1964 to 1972. They were
hooking it up to devices with a different kind of metal, and the alloy they were using in the
aluminum was downright inferior. There were lots of problems with the aluminum expanding
while hot and contracting while cool. Thats a good way to get loose connections, not to mention
oxidizing and reacting to dissimilar metals. Oxidation on aluminum is a big deal because
aluminum oxide (a fine white powder) is an insulator, not a conductor. Sure enough,
documented aluminum wire failures in the 60s included about 155 house fires, and several
deaths in Texas, New York, and New Jersey. The aluminum industry knew they had a problem,
and they began the steps to correct it.
The real problem was the wire itself. Beginning in 1972, aluminum wire is a modified alloy with
improved terminal retention, less expansion and contraction, and a much superior product to the
material that had been placed in over 2 million homes between 1964 and 1972. Modern
aluminum is an AA8000 series alloy, vastly superior to the pre-1972 material.
In 1972, the same year the aluminum wire industry introduced new alloys, congress approved
the Consumer Product Protection Act, which created a new agency, the Consumer Product
Safety Commission, which opened in 1973.
One of the first items to gain the new CSPCs attention was aluminum wire. The industry was
able to convince the CPSC of the improvement in the new alloys, but the commission was
concerned with the issue of whether the existing pre-1972 aluminum wire should be recalled.
The aluminum industry faced the financially disastrous prospect of having to rewire all these
houses, and searched for another solution.
Everyone agreed that aluminum by itself was an adequate conductor, but the problems at the
terminations of pre-1972 old technology aluminum were causing fires. The aluminum industry
was able to point to a solution the copalum connection system from Amp Industries. With
this system, a short copper pigtail was placed next to the aluminum, and a crimping die joined
the two conductors with a permanent crimp. The resulting connection did not bring the copper
and aluminum into direct contact the die is actually a current-carrying component and the
connection was not plagued by the problems of joining dissimilar metals. The copper pigtail
could be safely connected to a switch or receptacle like any other copper wire.











Figure 3 - Copalum Connections
Convinced that a safe alternative existed, the CPSC backed away from their investigation into a
possible recall of the old technology aluminum, but not without a few other interesting
developments throughout the 1970s.
Everyone realized that the problem was at the connections at the wire terminations, so they
concentrated on the devices the aluminum connects to. They came up with circuit breakers,
switches, and receptacle outlets identified for Cu/Al connections. That worked OK with circuit
breakers, but the set-screw connections on the receptacles and switches were still failing.
Those products were later replaced by CO/ALR devices.

Figure 4 CO/ALR Receptacle
In addition to the CO/ALR receptacles, a number of other methods were attempted in the
1970s. These include connecting aluminum directly to the screw terminals of ordinary
receptacles, and the use of copper pigtails with ordinary wire nuts between the copper and the
aluminum.












Figures 5 & 6 Direct Wired Aluminum and Copper Pigtail with Old Style Wire Nuts
Neither of the methods in figures 5 or 6 is recognized (unless the receptacle in figure 5 is rated
CO/ALR) and the CPSC published a brochure regarding Copalum as the only known safe pigtail
method. In the 1970s and 1980s, a number of contractors cooperated with the retrofit program
by leasing the necessary equipment from Amp Industries. That includes the crimping dies, the
tool to perform the crimp, the heat shrink tubing to insulate it, and the heat gun to shrink the
tubing. This repair method was once widely available across the United States. The problem
with it was that many times the connections could not all be accessed with the tools. Many
repaired aluminum wire systems are really only partial repairs, and this method could give
consumers a false sense of security. The popularity of the system waned in recent years, and
today it is difficult to find contractors who can perform a Copalum repair.
Into this mix we find two other splicing methods that have a UL listing. First was split-bolt
connectors (figure 7) , and the next was a wire nut by Ideal that was introduced in February
1995 (figure 8). This wire nut contains an anti-oxidant paste encapsulated inside the connector.




Figure 7 Split Bolt Connector

Figure 8 Ideal 65 Wire Nut
Split bolt connectors with a separating plate are very labor intensive, and require a layer of
bulking tape and insulating tape. They also can easily crowd an existing box