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Aluminum Wire Repair by Copper Pigtailing: Instructions and Illustrations
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InspectAPedia tolerates no conflicts of interest. We have no relationship with advertisers, products, or services discussed at this website.
Aluminum Wiring Repair Procedure - Page 1 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.
Green links show where you are. © Copyright 2013 InspectAPedia.com, All Rights Reserved. Author Daniel Friedman.
A Description of Alumnum Electrical Wiring Repair Procedures, Which Repairs Work & Which Aluminum Wire Repairs Fail - US CPSC Presentation
Color photos of aluminum wire repair procedures, and photos of failed connectors are included.
This document series describes hazards with existing aluminum wiring repair 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.
Click any image to see an enlarged version.
1. Commonly used instruction for pigtailing using twist-on connector. This instruction has been widely published and distributed by UL, by trade journals and instruction books, and in the
National Electric Code Handbook. Since about 1985, until now, no twist-on connectors were listed by UL for this purpose.
2. Prior to 1985 most twist on connectors on the market were listed by UL as suitable for the purpose. The actual performance in this application varied widely, however, depending on the
construction and installation method.
3. The pigtailing application works this way. A short copper wire is spliced to the aluminum circuit wire. The copper wire is connected to the device terminal. The pigtail splices carry full
circuit current to downstream loads. With the best connector and method of installation, this could be a safe technique.
This article series continues with Copper Pigtailing and other links you 'll find below - just scroll down
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Technical Reviewers & References
Related Topics, found near the top of this page suggest articles closely related to this one.
- [1] AlumiConn™ AlCopStore.com
223 Salt Lick Road, #279,
St. Peters, MO 63376
Tel: 866-826-2256, Fax: 636-754-0500, Email Sales: pking@AlCopStore.com, Email General Inquiry: info@AlCopStore.com
- [2] "Repairing Aluminum Wiring," [As updated 2011] U.S. Consumer Product Safety Commission Publication CPSC#516 available online
- [3] "Record of Commission Action, Commissioners Voting by Ballot", CPSC Publication No. 516, Repairing Aluminum Wiring (original version op.cit.), (Briefing package dated March 15, 2011), Quoting:
The Commission voted unanimously (5-0)·to approve republication of CPSC Publication No. 516, Repairing Aluminum Wiring, with the explicit recognition that the COPALUM and AlumiConn connectors currently are the only products that meet the agency's standards to prevent aluminum wire fire hazards
Copy on file as /aluminum/Pub516_Alumi_Conn.pdf
- [4] Dr. Jess Aronstein, protune@aol.com is a research consultant and an electrical engineer in Poughkeepsie, NY. Dr. Aronstein provides forensic engineering services and independent laboratory testing for various agencies. Dr. Aronstein has published widely on and has designed and conducted tests on aluminum wiring failures, Federal Pacific Stab-Lok electrical equipment, and numerous electrical products and hazards. See Aluminum Wiring Bibliography and see FPE HAZARD ARTICLES, STUDIES for examples.
- [5] "The Influence of Corrosion Inhibitor and Surface Abrasion on the Failure of Aluminum-Wired Twist-on Connections",
Aronstein, J.; Campbell, W.,
Components, Hybrids, and Manufacturing Technology, IEEE Transactions on
Volume 7, Issue 1, Mar 1984 Page(s): 20 - 24
- [6] Thanks to reader Thomas Kremer
for suggesting clarification to this topic 08/09
- [7] Personal communication, Email, P. King to D Friedman, 3/10/2012 [copy on file AlumiConn_PK120310.pdf].
Books & Articles on Building & Environmental Inspection, Testing, Diagnosis, & Repair
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 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)
- ALUMINUM WIRE REPAIR METHODS to reduce risk in buildings with Aluminum Electrical Wiring - Overview of Acceptable Repair Practices (in the document you are presently viewing)
- Aluminum Wire 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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