First, a little history about aluminum wiring: During the mid 60’s and into the mid
70’s and throughout the Vietnam War era, copper was at an all time high price
level, which made it cost prohibitive for use in residential wiring. (Actually, it was
nowhere near as expensive as it is today.) Copper mining and processing was
not what it is today, production could not keep up with demand, and the copper
was being bought up at a rapid pace to provide jacketing for ballistics in the
military and for other military purposes. People in the home building industry
were looking for an alternative product that could be used safely for residential
wiring and it was determined that aluminum would suffice, if it was installed
correctly. Underwriters Laboratories had previously approved aluminum for
interior wiring purposes as early as 1945. Of course there were some issues that
needed to be considered by the industry if we were going to use aluminum for
circuits in homes. It was much softer than copper wiring, it couldn’t withstand as
much stress when it was being pulled, it was subject to breaking if it was nicked
and bent at radical angles, and it had to be at least one wire gauge larger than
copper for each current rating. But, despite all of the downfalls of aluminum, it
was much cheaper to use at the time and it would have been an acceptable
product for the purpose if it were installed correctly. Not much emphasis was put
on aluminum wiring’s creep rating (rate of expansion and contraction) and very
little information was disseminated to the end user’s about the proper installation
of aluminum wiring. Builders and electrical contractors were just happy to have a
cheaper product to use that would enable them to continue building. During that
time there was widespread use of 12 AWG and 10 AWG type NM-C sheathed
aluminum cable in the interior wiring of homes. Local building inspection
departments and code enforcement agencies were very scarce during this era
and probably had even less information than the electrical contractors did about
the installation of aluminum wire.