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Repairing Aluminum Wiring US Consumer Product Safety Commission Publication #516

NOTE: This document has been scanned verbatim from the CPSC document and is straight ASCII text except where we have inserted the graphics images.

REPAIRING ALUMINUM WIRING

U.S. Consumer Product

° On April, 28,1974, two persons died in a home fire in Hampton

Bays, New York. Fire officials determined that the fire was caused by a

faulty aluminum wire connection at an outlet.

° Since that tragic accident, the U.S. Consumer Product Safety

Commission staff and other government officials have investigated

numerous complaints from homeowners throughout the nation who

have had trouble with small gauge aluminum branch circuit wiring. The

Commission has also had research conducted that shows that 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 is a home wired

° The hazard investigated by the Commission staff occurs at

connections to old technology aluminum wire, such as at outlets or

switches or at major appliances such as dishwashers, furnaces, etc.

Corrosion of the metals in the connection, particularly the aluminum

wire itself, causes increased resistance to the flow of electric current

and that resistance causes overheating.

° Homes built before 1965 are unlikely to have aluminum branch

circuit wiring. Homes built, rooms added, and circuits rewired or added

between 1965 and 1973 may contain aluminum wiring.

° In 1972, manufacturers modified both aluminum wire and switches

and outlets to improve the performance of aluminum wired

connections. Sale of the old style wire, switches and outlets still on

dealers' shelves however, continued after 1972.

° Signs of trouble in aluminum wire systems include warm-to-the-

touch face plates on outlets or switches, flickering lights, circuits that

don't work, or the smell of burning plastic at outlets or switches.

Unfortunately, not all failing aluminum wired connections provide such

easily detected warning signs; aluminum wired connections have

been reported to fail without any prior indications or problems.

1 (footnote) The survey conducted by the Franklin Research Institute defined

"Fire Hazard Conditions" to occur when receptacle coverptate mounting screws

reached 149~C (3O0~F), or sparks were emitted from the receptacle, or materials

around the receptacle were charred.

WHAT THE HOMEOWNER CAN DO

° If you have noticed any of the trouble signs, have a qualified

electrician determine whether the problem is caused by deteriorating

connections to aluminum wiring. DO NOT TRY TO DO IT YOURSELF.

You could be electrocuted or you could make the connections worse

by disturbing them. If you are not certain whether your home has

aluminum branch circuit wiring, you may be able to tell by looking at the

If you do have aluminum branch circuit wiring, the Commission

suggests that you have a qualified electrician check the system for

impending trouble. Remember, you may not have noticed any of the

warning signs, but research shows that trouble may develop over time

and an electrician may spot potential problems before you notice

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