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ELECTRICAL INSPECTION, DIAGNOSIS, REPAIR

ALUMINUM WIRING HAZARDS & REPAIRS
ALUMINUM-WIRED HOMES, REDUCE THE HAZARD
ALUMINUM WIRING BIBLIOGRAPHY
ALUMINUM WIRE FAILURE REPORTS
  240V Heat Pump Circuit
  Ideal-65 "Twister" Burnup in Field Use
  Electrical Panel Overheat
  Electrical Receptacle Burnup
  Copper to Aluminum Pigtail Overheat
  Twist-on connector overheating cases

ALUMINUM WIRING IDENTIFICATION
ALUMINUM WIRING RENTAL HOME ADVICE

ALUMINUM WIRING RISK REDUCTION
  ALUMINUM WIRE CHANGEOUT
  ALUMINUM WIRE ALUMI-CONN
  ALUMINUM WIRE COPALUM
  ALUMINUM WIRE SPLICES
  ALUMINUM WIRE GROUNDS
  MAKE SPACE FOR ALUMINUM CONNECTORS
  REDUCE THE AL WIRE RISK: DETAILS

ALUMINUM WIRING REPAIR ELECTRICIANS
ALUMINUM WIRING REPAIR, Other Products
ALUMINUM WIRING REPAIR COALR & CU-AL DEVICES

ALUMINUM WIRING REPAIR NOT-Recommended
  COALR or / CU/AL Devices
  HARBOR FREIGHT CRIMPER
  IDEAL-65 Purple Twister
  MARRETTE B-Cap Connector
  SCOTCHLOK 3-M Connector
  Wiring Repair Methods CPSC Meeting

ALUMINUM WIRING SAFETY RISKS
  Aluminum Wiring - CPSC Publication #516-PDF
  Aluminum Wiring - CPSC Publication #516-HTML

Aluminum Wiring Notes for Home Inspectors
Aluminum Wiring Summary Page for Public Use

AMPS VOLTS DETERMINATION
AMPACITY - the LIMITING FACTOR
APPLIANCE EFFICIENCY RATINGS

BACKUP ELECTRICAL GENERATORS
BUILDING SAFETY HAZARDS GUIDE
BOOKSTORE - ELECTRICAL

Cadet & Encore Heater Recall
CIRCUIT BREAKER FAILURE
Classified CIRCUIT BREAKER WARNING
CIRCUIT BREAKER SIZE for A/C or HEAT PUMP
Classified CIRCUIT BREAKER WARNING
CUTLER HAMMER PANEL FIRE
CONDUIT, ELECTRICAL
CORROSION in ELECTRICAL PANELS
CORROSION & MOISTURE SOURCES in PANELS

DEFINITIONS of ELECTRICAL TERMS
DIRECTORY OF ELECTRICIANS
  DIRECTORY OF ELECTRICIANS - Aluminum Wiring
  DIRECTORY OF ELECTRICIANS - FPE Zinsco

ELECTRIC HEAT
ELECTRIC HEAT
ELECTRIC METERS & METER BASES
ELECTRIC MOTOR DIAGNOSTIC GUIDE
ELECTRIC MOTOR OVERLOAD RESET SWITCH
ELECTRIC PANEL AMPACITY
ELECTRIC PANEL INSPECTION
ELECTRIC PANEL MOISTURE
Electric Power Frequency Table
ELECTRICAL BASICS
EMF RF FIELD & FREQUENCY DEFINITIONS
ENERGY SAVINGS in buildings
ELECTRICAL GENERATORS
ELECTRICAL GROUND SYSTEM INSPECTION

FEDERAL PACIFIC FPE HAZARDS
FIRE SAFETY Checklist, CPSC

GENERATORS, ELECTRICAL
GFCI PROTECTION,Testing GFCIs AFCIs

HEATING COST FUEL & BTU Cost Table
HEAT, ELECTRIC
HEAT TAPE USAGE GUIDE
Hertz - Definitions of KHz MHz GHz THz

KNOB & TUBE WIRING

LIGHTING, EXTERIOR GUIDE
LIGHTING, INTERIOR GUIDE
LIGHTNING PROTECTION SYSTEMS
LOW VOLTAGE BUILDING WIRING

MAIN DISCONNECT
MAIN DISCONNECT AMPACITY
MOISTURE SOURCES in PANELS
MULTI-WIRE CIRCUITS
MURRAY SIEMENS Recall

PHOTOVOLTAIC POWER SYSTEMS
PUSHMATIC - BULLDOG PANELS

REMOTE ELECTRIC POWER, PHOTOVOLTAIC
RUST in ELECTRICAL PANELS

SAFETY for ELECTRICAL INSPECTORS
SE CABLE SIZES vs AMPS
SIEMENS MURRAY Recall
SQUARE-D RECALLS

THERMAL EXPANSION of MATERIALS

UNDERGROUND SERVICE LATERALS
VOLTAGE MEASUREMENT EQUIPMENT

WIND ENERGY SYSTEMS
WIND TURBINES & LIGHTNING

ZINSCO / SYLVANIA HAZARDS

More Information

Photograph of an overheating aluminum-wired electrical outlet - thanks to J Simmons. Aluminum Wiring Failures in Residential Properties: Field Reports & Pictures
InspectAPedia®  -      

  • Photographs of aluminum wire overheats and failures
  • Field reports of aluminum wiring failures or fires
  • Questions & answers about aluminum electrical wiring field failure reports

This article contains photo-documented reports of actual in-service aluminum wiring failures in homes. I have been receiving reports from home owners, builders, and building professionals since 1990. However this page was created in July 2004, so it will not contain all of the historical data.

InspectAPedia tolerates no conflicts of interest. We have no relationship with advertisers nor with topics or services discussed at this website.

Recent reports, photographs, anecdotes will be displayed here. When I complete statistical analysis of prior reports I'll add that data at this page. Readers should also see the Aluminum Wiring Website home page.

© Copyright 2012 InspectAPedia.com, All Rights Reserved. Information Accuracy & Bias Pledge is at below-left. Use page top links to major topics or use links at the left of each page to navigate within topics and documents at this website. Green links show where you are in a document series or at this website.

Aluminum Wiring Overheating Reports with failure photographs

240V Heat Pump Circuit - Aluminum Wiring Failure Case

  • Improper use of twist-on connector, overheat, melt, fire prevented by steel box "I was replacing the heat pump unit on our home and went under the house to wire in the new unit to an existing junction box. Upon opening the box I let out an expletive and then went right to our local home center to purchase some new copper wire to run from the service panel to the new unit.

Whoever wired the previous unit must have had some Al wire around but not quite enough to reach the unit, so they used a junction box to connect Al and Cu wire. Fortunately, the so-called technicians used a steel box otherwise the house could have burned down. This was the only aluminum wiring I have found thus far but I'm not done inspecting yet."-- J.F. 6/30/2004 DF-note: see also this lab photograph of an overheating twist-on connector to show the overheat mechanism in the case above

Ideal-65 "Twister" Burnup in Field Use - Aluminum Wiring Failure Case Photos


  • Ideal 65 Purple "Twister" Field Burn-up-1
    , from Alex Costantino

  • Ideal 65 Twister Field Burn-up-2
    , from Alex Costantino


  • Ideal 65 Twister Field Burn-up-3
    , from Alex Costantino


  • Ideal 65 Twister Field Burn-up-4
    , from Alex Costantino


  • Ideal 65 Twister Field Burn-up-5
    , from Alex Costantino

  • Additional details about this failure are at Mr. Costantino's Web Page about this case.

Electrical Panel Overheat - Aluminum Wiring Failure Case Photos


  • Aluminum Wire Overheat in Electric Panel
    , from J. Simmons - Electrician, 14 Mar 2006


  • Aluminum Wire Overheat in Electric Panel2
    , from J. Simmons - Electrician, 14 Mar 2006


  • Aluminum Wire Overheat in Electric Panel3
    , from J. Simmons - Electrician, 14 Mar 2006

Electrical Receptacle Burnup - Aluminum Wiring Failure Case Photos


  • Aluminum Wire Overheat at electrical receptacle
    , from J. Simmons14 Mar 2006


  • Aluminum Wire Overheat at electrical receptacle2
    , from J. Simmons 14 Mar 2006


  • Aluminum Wire Overheat at electrical receptacle3
    , from J. Simmons 14 Mar 2006


  • Aluminum Wire Overheat at electrical receptacle4
    , from J. Simmons 14 Mar 2006


  • Aluminum Wire Overheat at electrical receptacle5
    , from J. Simmons14 Mar 2006

 

Copper to Aluminum Pigtail Overheat - in Electric Panel, including infra-red Case Photos

  • Photograph of  this overheating and improperly-made aluminum to copper pigtail splice.
    Improper copper to aluminum splice
    does not use an approved connector and is visibly
    overheated both in this photo and in next IR photo below.

  • Photograph of  this overheating and improperly-made aluminum to copper pigtail splice.
    Infra red photo of overheating copper to aluminum pigtail
    in the splice shown above

  • Photograph of  this overheating and improperly-made aluminum to copper pigtail splice.
    Infra red photo of overheating connection
    aluminum to copper splice in an electrical panel

  • Photograph of  this overheating and improperly-made aluminum to copper pigtail splice.
    Infra red photo of overheating circuit breaker
    with aluminum wiring

Contributor - Gordon Cohen: These thermal imaging photos of overheating aluminum splices and circuit breakers with aluminum wiring are courtesy of Gordon Cohen, June 2006. Mr. Gordon offers home inspections and thermal imaging services in Florida and is also employed by ServiceMaster as a project manager. Email: Infraredinspections@cfl.rr.com

Twist-on connector overheating cases - Forensic Engineer Reports

  • Aronstein reports and provides these additional examples of aluminum wiring field failures.

Questions & Answers regarding this article

Questions & answers about aluminum electrical wiring field failure reports.

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Use links just below or at the left of each page to navigate this document or to view other topics at this website. Green links show where you are in our document or website.

Books & Articles on Building & Environmental Inspection, Testing, Diagnosis, & Repair

  • Our recommended books about building & mechanical systems design, inspection, problem diagnosis, and repair, and about indoor environment and IAQ testing, diagnosis, and cleanup are at the InspectAPedia Bookstore. Also see our Book Reviews - InspectAPedia.
  • How to Reduce the Risk in buildings with Aluminum Electrical Wiring - Overview of Acceptable Repair Practices (in the document you are presently viewing)
  • 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
  • "Repairing Aluminum Wiring," U.S. Consumer Product Safety Commission Publication CPSC#516 available online
  • Directory of Home Inspectors accessible via Internet
  • ...

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