Is Aluminum Wiring Really That Bad?

Back in the 1960’s, copper wiring, which was commonly used in wiring homes, skyrocketed in price.  In order to cut costs, contractors started using aluminum wiring as it was more lightweight and less expensive.  However, it didn’t take too long before people started to realize the dangers of aluminum wiring.  By 1978, aluminum wiring was phased out due to safety concerns and copper wiring was back in common use.

If you own a home that was built between 1965-1978, or are looking to buy one from that time, it is best to understand the risks in aluminum wiring, which your home likely has.

What Makes It So Dangerous?

Aluminum has a bad reputation among electricians these days, and for good reason.  Homes with aluminum wiring are 55x more likely to catch fire.  That is a substantial difference from copper wiring.  But what exactly makes it so dangerous?

1.    Aluminum wires are prone to aluminum oxide

Heat oxidizes aluminum, which makes it very resistant to heat.  This heat resistance creates excess heat and connection issues.  This causes a fire hazard.

2.    Aluminum is softer than copper

Being more lightweight and flexible than copper, this was originally an appeal to electricians in the 60’s and 70’s.  However, over time, electricians realized that the flexibility of copper wiring caused it to expand with heat and shrink as it cools.  Due to this, connections loosen and weaken.  This is a major hazard.

3.    Aluminum is prone to creeping

Aluminum’s flexibility leads to a problem commonly referred to as ‘creeping’.  Creeping is the term used to describe when the wiring slowly deforms over time due to heat exposure. Deformed wiring is also a dangerous hazard to your safety.

How Do You Know If You Have Aluminum Wiring?

So we’ve established that aluminum wiring is incredibly hazardous, what now?  If you own a home from 1965-1978, it is best to check if your wiring is aluminum.  There are a couple ways you can check yourself:

1.    Check the Label or Wire itself

If there is anywhere in your home that has exposed wires such as an unfinished garage or attic, you can check there.    Aluminum wires will often be labeled ‘AL’ or ‘ALUMINUM’.  If you open up your panel or even a receptacle or switch out of the wall you can see if the wire is silver in color. Be aware however, there were wires that were installed called copper clad. These wires are copper with a tin coating and do not pose the same threat as aluminum wiring. Because these are also silver in color, you could easily mistake it for aluminum wire.

2.    Hire a Professional

Hiring a licensed electrician to inspect your wiring is a more reliable way to know you have aluminum wiring as they are trained to know what to look for.  They also have the proper tools to do the job safely.

What Should You Do About It?

1.    A Full-House Rewire

A full-house rewire will eliminate the threat aluminum wiring poses by replacing it with copper wiring.  However, it is a costly undertaking.  Even though this is the solution we would highly recommend, we also understand that it may not be in the budget.  That’s why there is another, more temporary solution:

2.    AlumiConn Connectors

AlumiConn connectors securely joins aluminum and copper wires inside a special insulated connector with set screws.  It is easy to install, but it’s not as reliably safe as a full rewire.  But its affordability makes it a viable option for homeowners of older homes who want to put off a full rewire. Alumicons are also large in size relative to the normal size boxes that were used back then. If alumicons are used then a new modern box will have to replace the old one.

3. Purple Wirenuts

Purple wire nuts are rated for the same thing as alumicons but are smaller in size. These can be used in lieu of alumicons to prevent from having to change the box. However, they have to be carefully managed when creating pigtails, which is the process of attaching a piece of copper wire to the aluminum wiring so as to put it on the outlet. This is a dubious install because they still take up a lot of room in the box and they can also break the aluminum wire being connected if not done properly.

4. CU/AL Rated Outlets and Switches

This would be the least costly and most reliable of all three methods. These are outlets specifically rated for aluminum wires and there would be no extra wires or devices to fill the boxes that hold them.

What NOT To Do About It

There is often a temptation among many homeowners to DIY projects such as this, but dealing with wiring, especially older wiring, is very dangerous for anyone without the proper tools and expertise to fix it.  Do NOT try to fix aluminum wiring yourself.  If you suspect you may have aluminum wiring, relying on licensed electricians is always the safest decision.

Why Copper?

Copper wiring was what was commonly used before builders made the more affordable switch to aluminum, and when aluminum was being phased out, copper was returned to its place as builders’ and electricians’ first choice.  But what about it makes it such a desirable material for wiring?

-It's a better conductor than aluminum. It takes a larger size aluminum wire to have the same conductivity as a copper wire that is smaller.

-It’s durable.  It is much more resistant to corrosion and oxidation than aluminum, so there's less maintenance needed to keep your home safe. Copper is more forgiving than aluminum when using wirenuts or landing it on devices if not done correctly.

-It’s less of a fire risk.  Copper doesn’t expand and shrink like aluminum does, which keeps its connections secure, making it less likely to cause fires.

Rewiring is a major undertaking, especially if you have a larger home, but switching your aluminum wiring for copper is the safest route you can take.

In Conclusion….

Aluminum wiring, though once heralded as a cheaper option for homes, has gained a reputation as a dangerous material for wiring, and for good reason.  If you own a home built between 1965-1978, it would be wise to check your wiring.  If it’s aluminum, consider having your house rewired, or at least having AlumiConn connectors installed.  If you need an electrician for the job, Electricians of Dallas is here for you.  Give us a call at 972-418-0691 for a free estimate.