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Aluminum Wire: Examples of aluminum wire field failures in electrical circuits

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Aluminum Wiring Repair Procedure - Page 4 Color photos and descriptive captions from CPSC Meeting 9/28/95. In this document aluminum wire twist-on connector failures and repair procedures are described, including aluminum wire repair methods which work and methods which do not work and are unsafe. Color photos of aluminum wire repair procedures, and photos of failed connectors are included. This document describes hazards with existing products, explains the aluminum wiring failure mechanism, and reviews recommended retrofit procedures including use of readily-available materials. This information was presented to the US Consumer Product Safety Commission by Dr. J. Aronstein, 9/28/95. The minutes of that meeting were obtained under the Freedom of Information Act and posted by Daniel Friedman January 1996.
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10. Field failures are also seen. These were from an aluminum-wired senior housing complex in the DC area. A large number of these twist-on connector splices were found with various degrees of heat damage in an on-site inspection in which CPSC participated. (Photo courtesy of Tom Donahue)



11. The earliest visible sign of overheating is often softening and melting of the wire insulation, as in this field failure.




12. This field failure shorted to ground when the thermoplastic insulating shell softened due to overheating in the connector-spring area. Short circuits, due to insulation deterioration on the connector or wire, add to the fire hazard posed by the failure of aluminum-wired twist-on connections.



13. This field failure is from Canada, where they had a substantial number of aluminum-to-copper twist-on splice failures in electric baseboard heater installations.



14. This field failure was in service 9 years. Failure of the aluminum-wired twist-on splices occurs in a relatively short time for a component of the permanent built-in wiring of a home.



15. Note the burn-back of the wire insulation and the characteristic discoloration pattern on the connector shell of this field failure. (Photo courtesy of Eleanor Posey)



16. This last field failure again shows the typical overheating band. A number of field failures have been shown to emphasize that they are not rare. Both UL and CPSC investigated field performance and uncovered a substantial number of failures, with the worst-case failures resulting in structural fire and fatalities.

Other examples of aluminum wiring field failures are documented here.
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More Information on Aluminum Wiring Hazards and Other Building Diagnostic Inspections and Repairs

• 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

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