Friday, January 10, 2020

A Brief History of Residential Electrical Wiring

This cable type was sometimes called Rat Wire because the coating was developed to have a bad taste to keep mice and rats away. In the early years of BX wiring, the rubberized fabric coating sheath was still being used . Copper usage is widespread because it is superior to aluminum in more ways than one. But that doesn’t mean you won’t find many homes with aluminum wiring. The mass adoption of aluminum meant that builders would change because of consumer complaints.

when was aluminum wiring used in home construction

The wiring itself isn’t a problem; aluminum conducts electricity safely. It has come to my recent understanding that most insurance companies in Orlando and Central Florida are not insuring homes with aluminum wiring. There was a time that you could buy and sell a home by simply inspecting, repairing or installing pigtails at all outlets within the home.

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It may melt the wiring’s insulation and is a potential fire hazard. In the early 1970s, the alloy used for aluminum wiring was changed to a superior quality wire much better suited to use for electrical work. If it continues to deform, connections can become loose. More colloquially, the same cable loosens when it is bolted to a connection in excess and causes resistance to current flow.

"Pig-tailing" which involves splicing a short length of copper wire to the original aluminum wire, and then attaching the copper wire to the existing electrical device. The splice of the copper pigtail to the existing aluminum wire can be accomplished with special crimp connectors, special miniature lug-type connectors, or approved twist-on connectors . Pig-tailing generally saves time and money, and is possible as long as the wiring itself is not damaged. Flickering lights could be caused by several things, including loose bulbs or issues with the light fixture, but this may also indicate poor electrical connections due to deteriorating aluminum wires.

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The signs we highlighted earlier make the issues easily identifiable, including warm cover plates, overheating, and flickering lights. Overheating is the primary cause of fires by aluminum wiring. It can overheat more than copper, which means the coating deteriorates over time, exposing the wires. Shortly after aluminum wiring became popular, some problems started to appear. These included flickering lights, warm cover plates on switches and receptacles, and burned insulation on wiring. There was an overheating issue, and overheating can mean fires.

Aluminum wire might become dangerous because the issues that make it inferior all contribute to it wearing down. This is a considerable cause for concern because having been built in the 60’s and 70’s homes with aluminum wiring are already quite old and may be at risk. Negative information about aluminum branch circuit conductors involves solid aluminum wire for branch circuits. In houses, multi-stranded aluminum wire is still common today for main feeder service wires and circuits like electric stoves. The main problem was a loosening of the wire connections due to the high rate of thermal expansion and contraction compared to copper, and homes with aluminum wiring were much more likely to have electrical fires.

When was aluminum wiring used in homes?

Many of these older homes have small main service panels that could stand upgrading anyway. For owners also faced with aluminum wiring in their homes, there are several viable repair alternatives. The homeowner may choose to replace the solid aluminum wire with copper wiring. It is also possible to make less invasive repairs by “pig-tailing” copper wires onto the solid aluminum at all connection points.

We’ve already seen why copper has wider usage than its wiring counterpart. Many homeowners and homebuyers wonder if aluminum wiring is safe. Unfortunately, no, unless you’re speaking of multi-stranded wire.

According to the Consumer Product Safety Commission, there are approximately two million homes and mobile homes constructed using aluminum wiring since 1965. If you are shopping for resale homes, and they were built between 1965 and 1972, there is a good chance that you will end up looking at homes that have aluminum wiring. Look for the connection terminals of wiring devices mark CO/ALR which means copper-aluminum revised, it is safe to make the connection change. If the wiring is visible you can look for the initials of the Al element on the plastic cover.

Handling the problem before you put the home on the market eliminates a lot of potential problems. Aluminum corrodes in the presence of humidity and other metals. Along with the most knowledgeable, professional electrical service. Some of the solutions they found improved the performance of aluminum considerably.

The AlumiConn® Connector by King Innovations was listed by UL® in mid-2006 for solid aluminum wire pig-tailing repair applications. As with all repair methods, the manufacturer’s installation instructions must be adhered to rigorously. Unlike, the Copalum® system, the AlumiConn® connector is readily available and does not require a special tool to use. The AlumiConn® connectors may be found on the shelf at big box retailers in many areas. Wide product availability can be both a blessing and a curse.

when was aluminum wiring used in home construction

Proper workmanship is even more critical with solid aluminum wiring. The fact that a suspect connection has not failed can change quickly when a new owner moves in. The new occupant’s usage patterns may vary significantly from the previous owners, i.e. they plug in a major appliance at that receptacle with a marginal connection. Because aluminum branch circuit wiring has a lower conductivity than copper wire, it requires a larger diameter wire.

As aluminum heats, it expands and retracts as it cools, causing loose connections in breakers, wiring connections, outlets, switches, and light fixtures. Aluminum wiring was first used as branch circuits around 1965 during a copper shortage and was used in homes until the mid-1970s. It’s the small 15 and 20 amp breakers in your electrical panel.The larger wires and the main power lines coming into the home are typically aluminum but do not have the same issues that the branch circuit wiring. The symptoms of problems with aluminum wire include flickering lights and signs of overheating, such as burned insulation or oddly warm cover plates. It can overheat more easily than copper and start electrical fires by slowly damaging its insulation and heating things around it. The issues are caused by oxidation and other factors that lead to overheating where the wiring is connected at splices, outlets, and light fixtures.

when was aluminum wiring used in home construction

Homes built between 1965 and 1975 were likely wired with aluminum. Between 1890 and 1910, a wiring system known as knob-and-tube was the principal system of installation. It was quite a dependable system for the time, and a surprising number of American homes still have knob-and-tube wiring functioning, where it is often found alongside more modern updates. Electricity was invented in the 19th century and mass adoption followed shortly afterward.

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