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ALUMINUM WIRING HAZARDS & REPAIRS
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Aluminum wiring repair failures at copper pigtail connections: Illustrations, photos, and explanation of overheating and failures at copper pigtail connections used to repair aluminum wire. In this article series aluminum electrical 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.
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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.
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4. Burnouts like this occurred when various UL-listed twist-on connectors were tested for the pigtailing application, installed as per the manufacturers' instructions. Poor test results for twist-on
splices with aluminum wire were reported by UL, Battelle, CPSC, and various wire and device manufacturers.
Aluminum Wiring Repair Failure Photos & Causes: overheating at copper pigtails using twist on connectors
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