Aluminum Dangers
Aluminum Wiring (shown at right) was used in the construction of roughly 1.5 million U.S. homes built between 1965 and 1973. According to a report published by the U.S. Consumer Product Safety Commission (CPSC), homes wired with aluminum wire manufactured before 1972 (“old technology” aluminum wire) are 55 times more likely to have one or more connections reach Fire Hazard Conditions than a home wired with copper
picture of burnt aluminum wiring and surrounding framing
So Why is Aluminum Wiring Hazardous?
Certain properties of aluminum can cause deterioration of connections, possibly presenting a fire hazard
picture of burnt wirenut
Temperature change
Aluminum expands and contracts more than copper when it heats up and cools down. This can cause connections to loosen over time, leading to arcing (sparks) and increased heat at connection points, which are common sources of electrical fires.
picture of burnt outlet
Higher Resistance
Aluminum has higher electrical resistance compared to copper. This means it generates more heat when current flows through it, which can lead to increased temperatures and potential issues with overheating
picture of burnt purple wirenut
Oxidation
Aluminum is more prone to oxidation and corrosion. When aluminum wires oxidize, they form a layer of aluminum oxide, which is not a good conductor of electricity. This increases resistance and heat, further raising the risk of fire.
The real issue
When current flows through a connection, the connection becomes warmer. The expansion of the aluminum, confined under a screw terminal, generates tremendous pressure, so that the metal “flows” into the empty spaces in the connector. When the electrical load is removed, the aluminum cools and contracts, and a gap forms between the wire and the connector. The slightly loose-fitting connection now has a higher resistance, and more corrosion forms in the gap, further increasing the resistance. The next time a heavy load is applied, the connection becomes even hotter, and so on, until one day the connection may burn out, or surrounding material may ignite
picture of burnt purple wire nuts
Burned Purple Wirenuts
CAUTION: Many electricians, recommend other repair methods that are less expensive than COPALUM crimp connectors. We agree with the CPSC that these repairs are considered unacceptable and “does not solve the problem of overheating present in aluminum branch circuits."
Pigtailing with the Purples
The most often suggested unacceptable repair; (“pigtailing”) involves attaching a short piece of copper wire to the aluminum wire with a twist-on connector sometimes called a wire nut (IDEAL Purple #65)
They just don't work
In CPSC-sponsored laboratory testing, some brands of twist-on connectors have performed very poorly. Accordingly, from what we have seen in the field, we agree with the Commission staff and can validate the laboratory testing in believing that this method of repair does not solve the problem of overheating present in aluminum branch circuits.
Untouched is better than purples
We have seen far more burnt purple wire nuts than any other device or connector, we have come to the observed conclusion that invigorating the aluminum by installing purple wirenuts is far more dangerous than leaving it alone to begin with.
picture of burnt purple inside switchbox
ALUMINUM WIRE REPAIR, WE PERMANENTLY REPAIR THE HAZARDS OF ALUMINUM WIRING!
Call us today for your aluminum wiring electrical safety inspection.
Your Safety is Our Business
CO Electrical License #6092
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