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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 (with special installation procedures). Pig-tailing generally saves time and money, and is possible as long as the wiring itself is not damaged.
A copper strip is formed into the shape of a cylinder, while it is being wrapped around an aluminum core and the edges of the copper strip are welded together. The assembly is then pulled through a die, where the cladded wire is squeezed and stretched while also improving the bonding between the copper and the aluminum core. [1]
Twist-on wire connectors are not generally recommended for use with aluminum wire in the United States. [1] The U.S. Consumer Product Safety Commission disapproves wire nuts for aluminum wire; instead, special crimp connectors are called for, and as of 2011 the CPSC asserted qualified, second-preference approval of a certain kind of screw ...
Thus, while the connectors are often updated in housing that had been built before 1972, the wiring itself, if replaced after 1972, would most likely have been replaced with copper, making the post-1972 variants of aluminum wire extremely rare.
Ceramic bushings protected each wire entering a metal device box, when such an enclosure was used. Loom, a woven flexible insulating sleeve, was slipped over insulated wire to provide additional protection whenever a wire passed over or under another wire, when a wire entered a metal device enclosure, and in other situations prescribed by code.
Power cables use stranded copper or aluminum conductors, although small power cables may use solid conductors in sizes of up to 1/0. (For a detailed discussion on copper cables, see: Copper wire and cable.). The cable may include uninsulated conductors used for the circuit neutral or for ground (earth) connection.
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