Aluminum wiring became popular in American homes in the 1960s and 1970s due to the high cost of copper. However, aluminum wiring has been linked to certain safety risks that require special precautions during installation. This article will provide an in-depth guide on how I safely installed aluminum wiring in my home.

Understanding the Risks of Aluminum Wiring

Before installing aluminum wiring, it is crucial to understand the potential risks and how to mitigate them. The main safety concerns with aluminum wiring are:

• Overheating - Aluminum wires heat up faster than copper when electricity flows through them. This can lead to melted wires and fires.

• Loose connections - Aluminum expands and contracts more than copper. This can cause wires to push out of outlets and other connection points, resulting in arc faults or shorts.

• Corrosion - Aluminum is more prone to oxidation and corrosion than copper. This can degrade connections over time.

To address these risks, aluminum wiring requires special connection methods and routine inspection. When installed correctly, aluminum can be safe. But caution is required.

Choosing the Right Materials

Using the proper materials is essential for safety. Here are the key components I used:

• Aluminum wiring - I used only wiring labeled CO/ALR. This denotes that it is alloyed with copper for improved conductivity and safety. Pure aluminum wire is too risky.

• CO/ALR compatible devices - Outlets, switches and other devices must be rated CO/ALR. Look for the label. Standard copper-rated devices can oxidize and corrode with aluminum wiring.

• Anti-oxidant paste - This special paste helps prevent oxidation at connection points. I applied it to all switches, outlets, and wire nuts.

• Large wire nuts - The wire nuts must be large enough to properly join the thicker aluminum wires. Under-sized nuts can loosen over time.

Making Safe and Secure Connections

Proper technique when joining the aluminum wires is vital for safe, maintenance-free connections:

• Twist wires together - I twisted the bare aluminum wire tightly together with the copper wire of the device. This maximizes surface area contact.

• Apply antioxidant paste - I liberally applied the special paste to the wires before securing the connection.

• Tighten securely - I made sure to tighten wire nuts and terminal screws well beyond "snug." Under-tightening can allow loose connections to form over time.

• No aluminum-to-aluminum - Two wires made of dissimilar metals should always be used. Never join two bare aluminum wires together.

• Check for pitting - I inspected wires for any pitting or corrosion as I wired the house. Pitted wires should be replaced.

Routine Inspection and Maintenance

Since aluminum wiring is susceptible to connection issues over time, I take these precautions:

• Check connections yearly - I check all switches, outlets and wire nuts for tightness. I re-tighten any loose connections and apply more anti-oxidant paste.

• Check for hot outlets - I use an infrared thermometer each year to scan for hot outlets, which can indicate a faulty connection.

• Replace old devices - Outlets, switches and wire nuts do wear out over decades. I replace them proactively every 10-15 years.

• Call an electrician for concerns - If I have any doubt about the integrity of a wire or connection, I call a licensed electrician to inspect and repair it.

Is Aluminum Wiring Right for You?

While aluminum wiring can be safe when properly installed, it does require vigilance. Before using aluminum wiring in your home, consider:

• Age of home - Aluminum wiring is highest risk in homes over 40 years old where connections may have degraded. Newer installations are generally safer.

• Accessibility - Aluminum wiring should only be used in accessible areas like attics and crawlspaces. It is very difficult to inspect and maintain wiring inside walls and under floors.

• DIY comfort level - Installing and maintaining aluminum wiring safely requires skill and vigilance. If you are not highly experienced and comfortable with electrical work, copper may be a better choice.

In summary, aluminum wiring can be safe if selected carefully and installed meticulously following best practices. But it does require careful maintenance and inspection over time. Assess your specific situation carefully when deciding if aluminum wiring is right for your home.