My memory (your mileage may vary) says use fixtures rated for aluminum wire
(marked CO/ALR). If I remember correctly (I investigated 20 years ago for
aircraft installation), the failure of aluminum was often due to the
aluminum "creeping" or cold-flowing under the pressure of screws creating a
loose connection. Once loose, the joint heated and flowed more, with the
cycle repeating until bad things happened. Spring loaded fasteners kept the
pressure on even as the aluminum crept, but screws seemed to work if they
were designed properly. I was told that the aluminum could be reliable if
the proper CO/ALR components were used with it. They may be hard to find
these days or it may be everything is dual use now.
Since I thought giving advice on this might be ill-advised, I did a quick
search and came up with this ancient CPSC pamphlet.
www.cpsc.gov/cpscpub/pubs/516.pdf It mentions Copalum splices which I then
remembered were the same things recommended for splicing aircraft wiring
from copper to aluminum. They don't seem to recommend the CO/ALR fixtures
as a "complete" repair because they're not available for all fixtures in the
house. Lots of other sites were out there when I searched "repairing
aluminum wiring". Copalum splicing seems to be the only universally
recommended repair short of replacing it all with copper.
Another useful site was
http://www.thehartford.com/corporate/losscontrol/SBA/TIPS/680-400.pdf. You
can always count on insurance companies to limit losses. They seem to like
the CO/ALR devices better. This guy seems to offer some pretty good advice
and updates some of the recommendations (and says that Copalum in not widely
availabel today) http://www.homeinspectionplus.com/alumwire.pdf
Either way, it seems it would be a good idea to inspect all the fixtures for
signs of overheating. The big trick will be if you change anything to make
sure that you're improving things versus making them worse. Good luck, and
if in doubt there's always the National Electrical Code.
Ben Zwissler (not a licensed electrician)
bjzwissler@comcast.net
Columbus, IN
1966 TR-4A IRS
1973 MG Midget 1275
1980 TR-8
2003 Honda ST1300
-----Original Message-----
From: shop-talk-bounces+bjzwissler=comcast.net@autox.team.net
[mailto:shop-talk-bounces+bjzwissler=comcast.net@autox.team.net] On Behalf
Of Eric J Russell
Sent: Monday, September 29, 2008 10:26 PM
To: shop-talk
Subject: [Shop-talk] aluminum house wiring
My son bought a house built in 1969. I discovered that it has aluminum
wiring. Anything special I need to be aware of? Our plan is to replace
most of the switches & outlets to change from 'ivory' to white (plus
many have paint smeared on them from prior owner's painting efforts).
Eric Russell
Mebane, NC
http://home.mebtel.net/~ejrussell
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