Why Aluminum Wire?

Why Aluminum Wire?

For years, homeowners and DIY electricians have debated copper vs. aluminum wire, with aluminum getting a bad rap. While early aluminum wiring from the 1960s did have serious safety issues, modern alloys have made it a reliable, well-performing alternative to copper. Now, aluminum is safe, cost-effective, and the perfect fit for large-scale electrical projects. Still not sure which metal is for you?

Here’s what you need to know before making your choice.

A Look Back: How Aluminum Got Here

In the 1960s, a nationwide copper shortage drove the electrical industry to
look for affordable wire alternatives. They found aluminum– a lightweight,
inexpensive alloy that was comparable to copper in performance. This alternative
didn’t come without problems, though.

Back then, most at-home devices weren’t designed to receive power from
anything other than the copper standard. With rushed housing developments
using aluminum without knowing its drawbacks, issues started cropping up, like:

-Ampacity Issues (Overheating from undersized wire)
-Wire Creep (Loosening connections over time and stress)
-Brittleness (Due to using an untreated alloy)
-Electrical Fires due to a combination of all of the above

Given these challenges, it’s no wonder why copper stayed crowned as
the king of wire, and why many professionals grew to not trust aluminum.

The Turning Point: Standards and Technology Improvements

By 1972, manufacturers and electrician organizations took action. They
developed new standards and alloys to make aluminum safer and stronger.
The AA-8000 Series Aluminum Alloy became the benchmark— offering
improved tensile strength, better conductivity, and greater resistance to
temperature changes. These advantages made aluminum even closer to copper
in performance and reliability, especially for general building wire applications.

Nowadays, purchasing modern aluminum wire is a safe and up-to-code
decision that any cost-conscious electrician would be proud to make.

The Cost Advantage

One of the biggest selling points of aluminum is its price. On average,
aluminum sells for 2 to 3 times less than copper wire. When buying by the foot,
the discounted price adds up quickly for bulk projects like:

- Wiring a garage, shed, or workshop
- Running power to outbuildings
- Large-scale commercial or residential installations

Even when factoring in additional installation materials like anti-oxidant
paste or special connectors, the TCO ( Total Cost of Ownership) is much less
than a copper-based project.

If you’re unsure which size wire you need, check out our wire gauge sheet for quick reference.

What If My House Has Old Aluminum Wiring?

Finding 1960s-era aluminum in your home isn’t cause for panic. While
outdated wiring does require professional evaluation, it rarely means you need a
full rewiring. Electricians can retrofit old aluminum wire safely using:

- Special aluminum-to-copper connectors
- Anti-Oxidant paste to prevent corrosion
- Properly rated outlets and switches for aluminum conductors

This approach can modernize an older electrical system without the huge
expense of starting from scratch. If you need materials for repairs, browse our
aluminum electrical wire selection to find the right fit.

When to Choose Aluminum Over Copper

Copper is still unmatched in many applications— especially high-voltage
systems, sensitive electronics, and telecommunications. However, for many
general building projects, modern aluminum wiring delivers excellent
performance at a fraction of the cost.

Aluminum Shines Best When Used In:

- Service entrance cables
- Large feeder runs
- Outdoor detached structure wiring

Whatever the need, we carry both copper and aluminum wire— so you
can choose the best fit for your project.

The Bottom Line

Aluminum wiring’s bad reputation stems from decades-old problems that
modern standards have largely resolved. With today’s alloys and installation
practices, aluminum is safe, efficient, and cost-effective for many large-scale
applications.

If you’re planning an electrical project, consider the benefits of
aluminum— just make sure you work with a qualified electrician and follow
current safety codes. You might find it’s the perfect balance between
performance and price.

Let's Wire America!

Sources:

Arielesguerra. (2023, December 20). The true story behind aluminum wiring – part One. Home Inspection Training.

Grasby, S. (2012, November 26). Standard for Installing Aluminum Wire for Electrical Use Revised. ecmweb.com.

Hunter, C. (2006). Aluminum building wire installation and terminations. IAEI.