Frequently (Not) Asked Questions About Aluminum Cables

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Aluminum electrical cables are a popular wiring choice. However, are you fully informed about them? Here, we provide comprehensive answers to the questions you may not have thought to ask.

When did aluminum wiring become popular for residential use?

Following the discovery of electricity in the late 19th century, copper became the primary material for electrical wiring. However, during the 1960s, aluminum wiring emerged as a cost-effective alternative, eventually gaining preference over copper due to its affordability.

What is the manufacturing process for aluminum cables?

Aluminum is naturally found in the earth, typically as a silicate or oxide. The most common source is bauxite, which undergoes mining and refining. The refining process begins with the Bayer method, followed by heating and pressurizing the bauxite, which is then combined with sodium hydroxide. The final step involves smelting the material, resulting in 99.8% pure aluminum. For aluminum wiring, this pure aluminum is then shaped for sale to manufacturers, who subsequently draw it out to produce lengthy, flexible wires.

How do I decide between aluminum and copper wiring?

The decision hinges on various considerations. Aluminum wires are generally more economical, lighter, and have higher impedance. They also offer a larger diameter than copper cables with the same ampacity. However, aluminum wires are less elastic and have lower conductivity compared to their copper counterparts.

Do aluminum conductors require special connectors?

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Yes, connectors labeled "AL," indicating aluminum, are essential. Various types are available, so it’s important to select the correct one for your needs.

What is the maximum length available for aluminum cables?

There is no strict limit on the length of aluminum cables; they can be as long as necessary as long as accurate measurements are taken.

Is aluminum wiring safe for residential applications?

Aluminum wiring is entirely safe for home use if installed correctly.

What can be done to enhance the lifespan of aluminum wires?

Due to their susceptibility to mechanical damage, avoid any bending of aluminum wires during their installation. Additionally, it’s crucial to prevent any rubbing against other surfaces. Following installation and usage instructions meticulously is essential; improper environmental conditions can lead to overheating and malfunction.

How can I recognize aluminum wiring?

Identifying aluminum wires is straightforward—they exhibit a silver color and are marked with "AL" on their jackets. If you know that a house is built between the 1960s and 1970s (in the US), it's likely to have aluminum wiring. In homes constructed later, you may also notice "CO/ALR" markings, which denote that it is an aluminum wire with a copper-aluminum revised binding terminal.

Where can I purchase aluminum cables?

Nassau National Cable provides a wide variety of Aluminum Electrical Cables. Our extensive range includes Aluminum Home Feeder Cable, Aluminum SER Cable, Aluminum SEU Cable, and THHN THWN-2 Aluminum Cable among others. Explore our complete catalog or reach out to our support team to find the specific aluminum wiring you require.

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