Grounding Aluminum Wires

Where aluminum wire exists, and special connectors have not been provided, they should be added. In some cases it is difficult to know whether the connectors are appropriate. The safest thing is to replace them with those known to be appropriate. For example, the small solderless type connectors (e.g. wire nuts) are so small that they are not marked Cu-Al. They are now color coded, but on older ones it is difficult to know whether or not they are appropriate. Since they only cost a few cents each, it makes sense to replace them with those known to be the correct type.

Electrical outlets should be replaced with those designated CO/ALR. Service panels and their components, and other connectors designated by the utility should be replaced with components designated Cu-Al.

One alternative to using special connectors is to join the aluminum wires to short "pig-tails" of copper wire just before they connect to outlets, distribution panel terminals, et cetera. The connection between the aluminum and copper wire is made with a connector known to be appropriate. This is not recommended for two reasons. First, every connection added to an electrical system is one more potential problem area. Second, in some cases, the addition of one more connection in a junction box can lead to an overcrowding situation. However, the COPALUM system is an acceptable way to enhance the safety of aluminum wires.

In summary, the provision of the special connectors is not an expensive undertaking (usually a few hundred dollars if done by an electrician) and is well worthwhile. In many areas, the utility will inspect a house with aluminum wiring. Where there is evidence of a problem, they will insist that any dangerous flaws be corrected. However, this can hardly be considered a disadvantage, since a safe electrical system should be a priority for any homeowner. Where there is only a small amount of aluminum wire, it is often easier to replace it with copper wire than to replace all the connectors, especially if the service panel would have to be replaced.

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