What is aluminum wiring and is it safe in my New Brunswick home?

Aluminum Wiring in New Brunswick Homes: Safety and Solutions

Aluminum branch circuit wiring was installed in Canadian homes from approximately 1965 to 1976, when copper prices spiked and aluminum became the affordable alternative. Many New Brunswick homes from this era — particularly in suburban developments in Moncton, Fredericton, Saint John, and Riverview — have aluminum wiring.

Is Aluminum Wiring Dangerous?

Aluminum wiring itself conducts electricity safely. The danger is at the connection points — where aluminum wire meets outlets, switches, light fixtures, and panel terminals. The problems:

1. Oxidation
Aluminum oxidizes when exposed to air, forming aluminum oxide on the wire surface. Unlike copper oxide (which still conducts), aluminum oxide is an insulator. This creates resistance at connections, which generates heat.

2. Thermal expansion
Aluminum expands and contracts with temperature changes about 30% more than copper. Every time the wire heats (under load) and cools (load off), the connection loosens slightly. Over years, this creates progressively looser connections.

3. Galvanic corrosion
When aluminum contacts copper or brass (the material in most outlets and switches), galvanic corrosion occurs in the presence of moisture. This further degrades the connection.

4. Creep
Aluminum under sustained pressure (like a screw terminal) slowly deforms — a property called creep. This loosens connections over time even without thermal cycling.

The combined result: Over decades, aluminum connections develop high resistance, generate heat, and can ignite surrounding materials. Homes with aluminum wiring are statistically 55 times more likely to have connections reach fire-hazard conditions than homes with copper wiring (CPSC data).

How to Identify Aluminum Wiring

Look at the wiring in your panel, at outlets (turn off breaker first and pull an outlet from the box), or in the attic:

• Aluminum wire is silver-coloured (copper is orange/brown)
• Cable markings may include "AL" or "ALUMINUM" printed on the jacket
• Common cable types: NMDA or NMDS (aluminum versions of NMD copper cable)

If your NB home was built between 1965 and 1976, there's a reasonable chance it has aluminum wiring on some or all branch circuits.

Insurance Impact in NB

Aluminum wiring creates insurance complications similar to knob-and-tube:

• Some insurers refuse to insure homes with unmitigated aluminum wiring
• Others require an electrical inspection and proof of remediation (pigtailing or rewiring)
• Premiums may be 20–50% higher until remediation is documented
• When selling, buyers' insurance requirements often force the seller to address aluminum wiring before closing

Remediation Options

Option 1: Copalum crimping (gold standard)
A specially trained electrician uses the Copalum crimp tool to permanently join a short copper pigtail to each aluminum wire end. The copper pigtail then connects to the outlet, switch, or fixture. This method is endorsed by the CPSC and considered a permanent repair.

• Cost: $30–$50 per connection point
• Whole house (100+ connections): $3,000–$5,000
• Limitation: Copalum-certified electricians are rare in NB. You may need to find one specifically.

Option 2: AlumiConn connectors (widely available alternative) AlumiConn is a set-screw connector specifically approved for aluminum-to-copper connections. It uses a mechanical lug with anti-oxidant compound pre-applied. These are widely available and any licensed electrician can install them.

• Cost: $3–$5 per connector, $20–$40 per connection point including labour
• Whole house: $2,000–$4,000
• Approved by major electrical authorities as an acceptable repair method

Option 3: Complete rewire Replace all aluminum branch wiring with modern copper NMD90 cable.

• Cost: $10,000–$25,000+ depending on home size and accessibility
• Most thorough solution but also most expensive and disruptive
• Makes sense if the home needs other major electrical work (panel upgrade, additional circuits) at the same time

Option 4: CO/ALR devices Replace all outlets and switches with devices rated "CO/ALR" (Copper/Aluminum Revised) — these are specifically designed to accept aluminum wire safely.

• Cost: $5–$10 per device, $100–$200 labour per device
• Whole house: $1,000–$2,000
• Considered acceptable but less thorough than pigtailing. Addresses only the device connection, not junction box splices.

What NOT to Do

• Do not use standard wire nuts to connect aluminum to copper — standard wire nuts don't prevent oxidation and can create the same problems
• Do not use push-in (backstab) connections on aluminum — the spring clips lose grip as aluminum creeps
• Do not ignore it — aluminum connections degrade over time, and the fire risk increases with age
• Do not attempt DIY remediation — improper aluminum connections are more dangerous than no repair at all

Recommended Approach for NB Homeowners

Have a TSANB-licensed electrician inspect all accessible aluminum connections ($200–$400 diagnostic)

Pigtail with AlumiConn connectors at every connection point — outlets, switches, fixtures, junction boxes ($2,000–$4,000)

Apply anti-oxidant compound at panel connections

Document the remediation for your insurance company — get a written report from the electrician

Budget for full rewiring as a future project if major renovations are planned

The pigtailing approach is the most cost-effective solution that fully addresses the fire risk. It's a 1–2 day project for a licensed electrician and brings insurance compliance while protecting your family.

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