Electrical Inspection Service, Inc.

375 Dunton Avenue East Patchogue, NY 11772

Tel:(631) 286-6642 Fax: (631) 286-6683
www.EISLongIsland.com

Aluminum wiring installed in homes in the 1960’s and early 1970’s can be problematic. In
the early 70’s the U. S. Consumer Products Safety Commission (CPSC) conducted an
investigation that determined that a house wired with aluminum is 55 times more likely to
have branch circuit receptacles or switches reach a fire hazard threshold than houses wired
with copper wiring. This investigation noted the issues with aluminum wiring are:
 Poor workmanship – switches and receptacles were back wired, screws not torque
properly, wiring not full under screws, etc.
 Thermal expansion – significant different rate of expansion between the aluminum
conductor and the steel screw and plate.
 Cold and hot creep – aluminum conductor expanding out from under the steel screw
caused by over torqueing the screw or thermal expansion due to heat generated by
current flow.
 Aluminum oxidation – Raw aluminum coming in contact with air. Aluminum oxide has
very high resistance and causes heat build-up when current is flowing.
The CPSC did not address the poor tensile strength and fatigue of the aluminum wiring used
in the 60’s and 70’s (AA-1350) since this does not contribute to the fire hazard. The focus of
the CPSC investigation was on the fire hazards at the terminals of switches and receptacles
and did not address other electrical connections such as splices, lighting fixtures, other
electrical devices, grounding, etc.

The 1972 USCPSC report recommended three methods to remediate the fire hazard at
receptacles and switches:
1. Complete replacement of all branch circuit aluminum wiring with copper wiring.
2. Replace all switches and receptacles with devices listed (and tested) for use on
aluminum wiring identified by AL/CO markings. The AL/CO device had several
failures and is no longer permitted on aluminum wiring.
3. Pig-tailing - connecting the aluminum conductor(s) to a copper conductor using a
connector (wire-nut) then connecting the copper conductor to the receptacle or
switch.
Note that method 1 and 2 do not address all the other electrical connections in the branch
circuit.

Based on 1972 CPSC information the “Best Practice” for remanding the fire hazard
associated with aluminum wiring in the late 70’s, 80’s and early 90’s was to pig-tail the
aluminum wiring by cleaning the aluminum wire with a wire brush, coating the aluminum
wires with an oxide inhibitor, twisting the wires to make a good mechanical connection then
twist on a non-bakerlite wire nut.

In the 80’s and 90’s the CPSC reported additional failures at all aluminum wire connections
and
recommended that all splices, device connections and terminals need remedial repairs. In
the early
90’s several products came on the market to address specifically the issues of aluminum
wiring;
switches and receptacles were manufactured, listed and tested for connection to aluminum
wiring (CO/ALR), special types of crimp connectors were listed (COPALUM), wire nuts were
listed for copper only or for aluminum wiring and the alloy used for aluminum wiring was
changed (AA-88176).

The CPSC periodically updates its recommendations for aluminum wiring; the latest version
of the CPSC Publication 516 relating to remanding the fire hazards dated June 2011
approves only three methods: (page 3)
1. Complete replacement with copper conductor cable
2. COPALUM pig-tailing – COPALUM is a Tyco Electronic/Amp product that requires
certification by attending training in their facility in Harrisburg, Pa. and specialized
crimping tool with custom dies.
3. AlumiConn connectors – AlumiConn is a King Innovation product. The connectors
are small terminal strip with individual screws for both the aluminum and copper
conductors.
This CPSC publication recommends that all electrical connections, splices and terminations
be remedied using one of the above methods. It is interesting to note that the CPSC no
longer recommends CO/ALR devices but is still listed for this purpose.

As stated above, the CPSC did not address the poor tensile strength and fatigue of alloy AA-
1350 aluminum wiring that was used in the 60’s and 70’s. Aluminum alloy AA-1350 will break
very easily if nicked, sharply bent or bent several times. For this reason it is recommended
that the aluminum wiring, the devices and all the connections be disturbed as little as
possible. Only a licensed master electrician should repair, pig-tail and replace devices
connected to aluminum wiring.

Pig tailing or remanding aluminum wiring is not a requirement of the National Electrical
Code, consequently remanding or not remanding aluminum wiring is not a violation
providing listed material is used in accordance with the manufactures instructions.

Electrical Inspection Service, Inc. does visual inspections of aluminum wiring pig-tailing
using COPALUM crimp connectors or AlumiConn connectors only or device replacement
with CO/ALR devices. To pass the inspection all aluminum wiring connections, splices and
terminations from the start of the branch circuit must be pig-tailed or terminated on terminal
listed for aluminum wiring. The inspection must take place during the pig-tailing or device
replacement and all devices and splices must be out of the electrical box. The inspection
should be coordinated with our office in advance of the work.

The Consumer Product Safety Commission publication 516 can be downloaded at

www.inspectapedia.com/aluminum/CPSC_516._June_2011.pdf
I hope the above information is helpful and thank you for your attention.

Jerry Flaherty, CEI

Chief Electrical Inspector
Electrical Inspection Service, Inc.
(C) 631-774-8190
JerryFL@optonline.net