28 May
Why Aluminum Wiring in Older Homes Is Still a Safety Concern
Homes built between the mid-1960s and mid-1970s were commonly wired with aluminum branch-circuit wiring instead of copper. The problem is that aluminum expands and contracts more than copper with heat cycles, which causes connections to loosen over time and creates a real fire risk at outlets, switches, and fixtures.
If your home was built during that era and hasn’t had a licensed electrician assess it, it’s worth taking seriously. The U.S. Consumer Product Safety Commission has documented that homes with aluminum wiring are significantly more likely to experience fire hazard conditions than those with copper.
What Actually Happens Inside the Walls
The Expansion Problem
Every time a circuit carries a load, the wiring heats up slightly. Aluminum expands at a higher rate than copper when heated, then contracts as it cools. Do that thousands of times over 40 or 50 years and the wire starts to pull away from the terminal screw it’s clamped to. That gap is where arcing and heat buildup happen.
Oxidation makes it worse. Aluminum forms an oxide layer on its surface naturally when exposed to air. That oxide layer is actually a poor conductor, which increases electrical resistance right at the connection point. More resistance means more heat.
What Warning Signs Look Like
You might notice outlets that feel warm even when nothing is plugged in. Lights that dim briefly when an appliance kicks on. A faint burning smell near a wall plate that doesn’t go away. These are not minor annoyances. They’re signals that a connection somewhere in the circuit is failing.
Sometimes there are no visible signs at all, which is exactly why aluminum wiring inspections require opening devices and checking connections directly. A visual scan from the panel doesn’t tell the full story.
What the Fix Options Actually Are
Pig-Tailing with CO/ALR Devices
The most common repair approach is called pig-tailing: a short copper wire is spliced to the end of each aluminum wire using a connector listed specifically for aluminum-to-copper connections (look for the “AlumiConn” or “COPALUM” labels). The device side of the connection then terminates on copper only.
This method is accepted by most local authorities and is less disruptive than full rewiring. In the southwest suburbs, a lot of the older ranch-style homes in the area were built right in that aluminum-wiring window, so this type of repair comes up fairly regularly.
Full Rewiring
Pig-tailing solves the connection problem but doesn’t change the fact that aluminum conductors are still running through the walls. For homeowners who are doing a major renovation anyway, or who want the issue fully resolved rather than managed, whole-home rewiring with copper is the cleaner long-term answer. It’s a bigger project, but it also brings older homes up to current wiring standards in one shot. You can learn more about what that process involves on our wiring upgrades page for the Orland Park area.
If you’re in the early stages of figuring out what your home actually has, starting with an electrical inspection is the practical first step. An inspector can document exactly which circuits are aluminum, what condition the connections are in, and which approach makes the most sense for your specific house.
The Village of Palos Hills requires permits for electrical work, so any repair method you choose should be done by a licensed electrician who will pull the right permits and have the work inspected. That’s not just a formality. It protects you when it comes time to sell and keeps your homeowner’s insurance coverage intact.
For background on the research behind aluminum wiring risks, the CPSC’s aluminum wiring study is worth reading.
Related Questions
Can I tell if my home has aluminum wiring without calling an electrician?
Sometimes. Check the outer jacket of wiring visible in your attic, basement, or electrical panel. If it’s stamped with “AL” or “ALUM,” that’s aluminum. However, some homes have a mix of copper and aluminum on different circuits, and the only way to know the full picture is to have someone open the devices and examine the actual terminations.
Does aluminum wiring affect my homeowner's insurance?
It can. Some insurers charge higher premiums for homes with aluminum branch-circuit wiring, and a few will decline coverage or require repairs before issuing a policy. Disclosing it accurately matters, and documenting any repairs you’ve made with permitted work orders gives you solid footing with your carrier.