Original research · Code & safety
The Electrical Panels Insurers Won’t Cover, and How Many Homes Were Built When They Were Installed
Carriers decline, inspectors flag and sales fall through over three products — Federal Pacific Stab-Lok panels, Zinsco panels and aluminum branch-circuit wiring. Not one of them was ever recalled. Nobody had published how much of the housing stock sits in their installation era, so we counted it.
Written by HyreElectrical Research Desk Primary-source research and fact checking
The finding
67,068,006 US housing units — 47.1 percent of the entire stock — were built between 1950 and 1989, the era in which Federal Pacific Stab-Lok and Zinsco load centers were being installed.
A narrower window, the 34,739,491 units built in the 1960s and 1970s, contains the 1965-to-mid-1970s period in which aluminum branch-circuit wiring was going into new houses. These are counts of homes built in those years, not counts of panels or of wire.
Nothing in the Census records what is in a panel board, an unknown but large share of these products has already been replaced, and most homes of this age never had any of the three.
The finding worth carrying is the mismatch: the private insurance market treats these products as recalled, and the Consumer Product Safety Commission closed its Federal Pacific investigation in 1983 without ever determining that the breakers were unsafe, and without a recall.
Read this before you use any number on this page
The American Community Survey records the decade a housing unit was built.
It does not record the brand of the load center, whether the branch circuits are copper or aluminum, or whether any of it has been replaced since.
There is no dataset in the United States that counts installed electrical panels by manufacturer. If there were, this study would not exist.
So the quantity published here is exactly this: the number of housing units still standing that were built during the years these products were being installed.
Most of those homes never had a Federal Pacific or a Zinsco panel — the two brands were a minority of a competitive market — and of those that did, an unknown share have been upgraded in the forty to seventy years since.
Aluminum branch wiring is narrower still: CPSC puts it in new houses roughly from 1965 to the mid 1970s, which is a slice of one of our decade bands and cannot be separated from it, because the published table has no division finer than ten years.
What the count is good for is bounding the problem and locating it. It says the exposed stock is tens of millions of homes rather than hundreds of thousands, and it says where that stock is concentrated.
What it must never be used for is a sentence of the form “X million homes have Federal Pacific panels”. We have not written that sentence and it is not supported by anything below.
Why a construction-era count is the only count available
A homeowner discovers this problem in one of three ways, and all three arrive as a surprise. A home inspector photographs the panel during a sale and writes it up.
A carrier’s underwriting system flags the property and the renewal does not come. Or the buyer’s insurer quotes the policy conditional on the panel being replaced before closing, which turns a $2,000–$4,000 electrical job into a condition of the transaction.
In each case the homeowner asks the same two questions — how common is this, and is it actually dangerous — and finds that the first has no published answer at all.
Trade associations quote panel counts with no source. Contractor sites quote each other.
The federal government, which has investigated the hazard, has never counted the installed base, and the manufacturers that would know are gone: Federal Pacific Electric’s panelboard business was wound down in the early 1980s and Zinsco was absorbed into GTE Sylvania in 1973.
HYRE analysis. With no panel census in existence, the closest honest measure is the housing stock built while these products were on the market — an upper bound on the exposure, published as an upper bound. That is what follows.
It is the same reasoning a public-health study uses when it counts homes built before the 1978 lead-paint ban rather than homes with lead paint, and it carries the same weakness: the era is the proxy, not the hazard.
The national stock, by the decade it was built
Of 142,332,876 housing units counted in the 2023 five-year American Community Survey, 67,068,006 were built between 1950 and 1989 (margin of error ±64,313 at 90 percent confidence — a tenth of one percent of the estimate, which is as precise as national ACS figures get). That is 47.1 percent of everything standing.
Inside it, the 1970s are the single largest decade in the American housing stock: 20,484,570 units, more than any decade before or since.
That matters here, because the 1970s hold both the peak of Stab-Lok distribution and the tail of the aluminum branch-wiring period.
What each of those decades typically had installed in it — service size, wiring method, grounding — is set out in housing age and electrical systems.
Three different products, three different evidence bases
Federal Pacific, Zinsco and Challenger are named in the same sentence by insurers and they are not the same thing. One has a federal safety publication behind it. One has a closed federal investigation that reached no conclusion. One has neither.
Aluminum branch-circuit wiring — the strongest evidence of the three
This is the only one of the three with a current federal safety publication devoted to it.
CPSC Publication 516, Repairing Aluminum Wiring (June 2011), states that “a national survey conducted by Franklin Research Institute for CPSC showed that homes built before 1972, and wired with aluminum, are 55 times more likely to have one or more wire connections at outlets reach ‘Fire Hazard Conditions’ than homes wired with copper”.
The survey defined that condition as receptacle cover-plate screws reaching 149 °C, sparks emitted, or surrounding material charred.
On dates, CPSC is precise: “Homes built before 1965 are unlikely to have aluminum branch circuit wiring. Electrical cables installed between 1965 and the mid 1970s in new homes, in additions, and as part of rewired/new circuits may contain aluminum wiring.”
A mid-1960s copper shortage is the reason it moved from large-appliance circuits to general-purpose 15- and 20-amp circuits.
CPSC recognizes exactly three permanent repairs: complete replacement with copper, pigtailing with a COPALUM connector, and the AlumiConn connector.
The publication explicitly excludes copper-clad aluminum cable — marked “CU-clad” — from its recommendations, and excludes the larger-gauge aluminum used for service entrances, dryers and ranges, which is still standard and not the subject of any of this.
Federal Pacific Stab-Lok — an investigation that closed without a finding
CPSC opened an investigation into FPE Stab-Lok residential breakers in June 1980 and closed it in 1983.
The Commission’s own news release states it closed the matter “because the data currently available to the Commission does not establish that the circuit breakers pose a serious risk of injury to consumers”.
It also said it did so without making a determination as to the safety of FPE circuit breakers or as to the accuracy of the manufacturer’s position.
The stated reason was money. Staff estimated it would cost several million dollars to gather the necessary data, against a Commission budget of $34 million for the whole of fiscal 1983. The release records that the Commission can reopen the matter if further information warrants. It has not.
HYRE analysis. This is the crux of the page. “Never recalled” and “proven safe” are different statements, and so are “never recalled” and “proven dangerous”. The federal record supports neither of the strong claims made in either direction.
Independent laboratory work and civil litigation have gone further than CPSC did, and a homeowner is entitled to weigh that — but a page that tells you the government recalled these panels is telling you something that did not happen.
Zinsco — the thinnest federal record, the same market treatment
Zinsco panels, sold in volume through the 1950s, 1960s and early 1970s and later branded GTE Sylvania after the 1973 acquisition, carry no CPSC recall and no CPSC safety publication of their own.
The concern described by inspectors is a specific one — breakers whose aluminum bus connection can fail to trip while appearing seated — and it is documented in inspection practice rather than in federal safety literature.
HYRE analysis. Zinsco is the clearest case of the gap this page exists to describe: an underwriting rule with real financial consequences, resting on an evidence base that the federal government has never assessed either way.
What “recalled” means in an underwriting guide
One of the carrier documents quoted below lists as ineligible any panel “subject to a recall”, in the same breath as Federal Pacific and Zinsco. Neither product was ever the subject of a CPSC recall. The FPE investigation closed in 1983 with no determination; Zinsco was never the subject of a federal investigation at all.
HYRE analysis. That is not necessarily an unreasonable underwriting position. An insurer is pricing a loss distribution, not adjudicating a product-safety case, and it is free to decline a risk on inspection evidence the federal government never funded itself to test.
But it does mean a homeowner who is told “these were recalled” has been told something untrue, and the true version is stranger: this product was never cleared and never condemned, and the market settled the question the regulator left open.
What two named carriers actually publish
| Carrier | Document and date | What it says | Route back to eligibility |
|---|---|---|---|
| Orion180 Insurance Company | Texas Flex Program Underwriting Guide, Homeowners Program — 13 January 2025 | Lists as ineligible: “Knob and tube wiring… Aluminum wiring… Double-tapped wires… Unsafe electrical panels, including but not limited to: Fuse boxes… Federal Pacific Electrical (FPE)… Zinsco/GTE Silvania… Challenger.” | None stated. The risk is ineligible for the program. |
| Homeowners of America Insurance Company | Texas Homeowners underwriting guidelines, ineligible risks — no revision date published on the page; retrieved 5 September 2026 | Lists as ineligible: “Risks with Aluminum or knob and tube wiring.” | Aluminum wiring “may be eligible if properly modified, pig-tailed; proof from a licensed electrician will be required.” |
Two carrier underwriting documents, quoted from the carrier’s own publication rather than from commentary about it. Both are Texas programs; both were the guidelines publicly retrievable on 5 September 2026.
This is not a survey of the market. Underwriting guidelines are commonly confidential, and the two published here are the ones we could retrieve in full and quote exactly.
They demonstrate that the rule exists and what it says; they do not establish how many carriers apply it, and we make no such claim.
Guidelines change without notice — check the current version with the carrier, not with this page.
Every state, ranked by the share of its stock built 1950–1989
| # | State | Housing units | Built 1950–1989 | ± MOE | % of stock | Built 1960–1979 | % of stock |
|---|---|---|---|---|---|---|---|
| 1 | Hawaii | 564,905 | 337,770 | ±3,553 | 59.8% | 208,065 | 36.8% |
| 2 | Alaska | 327,610 | 191,761 | ±2,764 | 58.5% | 96,975 | 29.6% |
| 3 | California | 14,532,683 | 8,317,350 | ±20,382 | 57.2% | 4,308,940 | 29.6% |
| 4 | Connecticut | 1,536,049 | 828,830 | ±6,767 | 54.0% | 409,418 | 26.7% |
| 5 | Oklahoma | 1,763,036 | 922,874 | ±5,994 | 52.3% | 509,484 | 28.9% |
| 6 | New Mexico | 949,524 | 490,560 | ±5,549 | 51.7% | 249,309 | 26.3% |
| 7 | Louisiana | 2,094,002 | 1,077,371 | ±8,854 | 51.5% | 598,135 | 28.6% |
| 8 | New Jersey | 3,775,842 | 1,936,388 | ±10,624 | 51.3% | 958,315 | 25.4% |
| 9 | Maryland | 2,545,532 | 1,291,928 | ±8,738 | 50.8% | 635,679 | 25.0% |
| 10 | Michigan | 4,599,683 | 2,330,313 | ±9,921 | 50.7% | 1,226,721 | 26.7% |
| 11 | Florida | 10,082,356 | 5,092,695 | ±19,480 | 50.5% | 2,471,969 | 24.5% |
| 12 | Mississippi | 1,332,811 | 651,340 | ±6,146 | 48.9% | 369,420 | 27.7% |
| 13 | Virginia | 3,654,784 | 1,786,398 | ±10,300 | 48.9% | 903,720 | 24.7% |
| 14 | Wyoming | 275,131 | 134,517 | ±2,618 | 48.9% | 72,705 | 26.4% |
| 15 | New Hampshire | 644,253 | 314,199 | ±4,246 | 48.8% | 147,121 | 22.8% |
| 16 | Ohio | 5,271,573 | 2,541,509 | ±11,727 | 48.2% | 1,361,166 | 25.8% |
| 17 | Alabama | 2,316,192 | 1,110,852 | ±7,831 | 48.0% | 607,416 | 26.2% |
| 18 | Kansas | 1,285,221 | 612,875 | ±5,779 | 47.7% | 308,309 | 24.0% |
| 19 | Missouri | 2,809,501 | 1,332,554 | ±8,534 | 47.4% | 721,484 | 25.7% |
| 20 | Arkansas | 1,382,664 | 654,161 | ±6,563 | 47.3% | 370,158 | 26.8% |
| 21 | Illinois | 5,443,501 | 2,567,099 | ±11,712 | 47.2% | 1,408,591 | 25.9% |
| 22 | Kentucky | 2,010,655 | 941,504 | ±7,996 | 46.8% | 519,715 | 25.8% |
| 23 | West Virginia | 859,653 | 400,812 | ±4,899 | 46.6% | 209,343 | 24.4% |
| 24 | Rhode Island | 484,615 | 224,462 | ±3,626 | 46.3% | 109,629 | 22.6% |
| 25 | Pennsylvania | 5,779,663 | 2,622,894 | ±11,976 | 45.4% | 1,298,834 | 22.5% |
| 26 | Tennessee | 3,095,472 | 1,397,688 | ±9,580 | 45.2% | 737,840 | 23.8% |
| 27 | Minnesota | 2,519,538 | 1,135,894 | ±6,713 | 45.1% | 592,105 | 23.5% |
| 28 | Colorado | 2,545,124 | 1,138,246 | ±7,210 | 44.7% | 618,291 | 24.3% |
| 29 | Oregon | 1,838,631 | 817,853 | ±6,358 | 44.5% | 487,384 | 26.5% |
| 30 | Nebraska | 855,631 | 379,470 | ±3,768 | 44.3% | 221,259 | 25.9% |
| 31 | Vermont | 337,072 | 149,012 | ±2,467 | 44.2% | 78,186 | 23.2% |
| 32 | New York | 8,539,536 | 3,768,961 | ±15,786 | 44.1% | 1,885,432 | 22.1% |
| 33 | Arizona | 3,142,443 | 1,378,191 | ±8,770 | 43.9% | 692,990 | 22.1% |
| 34 | Indiana | 2,953,344 | 1,297,978 | ±8,194 | 43.9% | 704,815 | 23.9% |
| 35 | Wisconsin | 2,750,750 | 1,206,225 | ±7,134 | 43.9% | 657,793 | 23.9% |
| 36 | North Dakota | 374,866 | 163,814 | ±2,611 | 43.7% | 93,136 | 24.8% |
| 37 | Texas | 11,890,808 | 5,173,989 | ±20,210 | 43.5% | 2,559,273 | 21.5% |
| 38 | Montana | 522,939 | 226,972 | ±3,262 | 43.4% | 125,855 | 24.1% |
| 39 | Massachusetts | 3,014,657 | 1,298,031 | ±8,754 | 43.1% | 638,213 | 21.2% |
| 40 | Delaware | 457,958 | 196,006 | ±3,373 | 42.8% | 97,983 | 21.4% |
| 41 | Washington | 3,262,667 | 1,397,170 | ±8,571 | 42.8% | 767,465 | 23.5% |
| 42 | South Carolina | 2,401,638 | 1,007,592 | ±7,726 | 42.0% | 506,434 | 21.1% |
| 43 | Georgia | 4,483,873 | 1,868,988 | ±12,303 | 41.7% | 914,203 | 20.4% |
| 44 | Maine | 746,552 | 311,250 | ±4,099 | 41.7% | 154,223 | 20.7% |
| 45 | North Carolina | 4,815,195 | 1,977,907 | ±10,682 | 41.1% | 983,653 | 20.4% |
| 46 | Iowa | 1,427,175 | 581,060 | ±4,861 | 40.7% | 338,837 | 23.7% |
| 47 | South Dakota | 402,364 | 161,917 | ±2,774 | 40.2% | 89,839 | 22.3% |
| 48 | Utah | 1,193,082 | 459,064 | ±4,497 | 38.5% | 250,430 | 21.0% |
| 49 | Idaho | 776,683 | 293,845 | ±3,867 | 37.8% | 173,231 | 22.3% |
| 50 | Nevada | 1,307,338 | 450,406 | ±4,900 | 34.5% | 230,855 | 17.7% |
| 51 | District of Columbia | 356,101 | 117,461 | ±2,997 | 33.0% | 59,145 | 16.6% |
US Census Bureau, ACS 2023 5-year table B25034. The 1950–1989 column is the four decade bands summed; the margin of error is the root sum of squares of the four component margins, at 90 percent confidence.
The 1960–1979 column is the window that contains the aluminum branch-wiring era and cannot be narrowed further in this table.
Ranked on the sixth column, not the fourth. California, Texas and Florida hold the most era-built homes in absolute terms — 8.3, 5.2 and 5.1 million — while Hawaii, Alaska and Connecticut have the largest shares.
Both readings matter and they answer different questions: volume tells a contractor where the work is, share tells a homeowner how ordinary their situation is locally.
Where the era-built stock actually is
The spread across states is narrower than most housing measures: from 33.0 percent in the District of Columbia to 59.8 percent in Hawaii, a range of under two to one. Eleven states have half or more of their housing stock in the 1950–1989 window.
The two ends of the distribution have opposite causes, which is worth stating because the map does not say it.
The District of Columbia is low because its stock is older than the window — 31.7 percent of it predates 1940 entirely, which puts it in knob-and-tube and early-conduit territory, a different set of problems that this page does not measure.
Nevada, Idaho and Utah are low because their stock is newer: they built most of their housing after 1990.
HYRE analysis. A low share is therefore not a clean bill of health.
The useful reading is the pair of columns together — a state high on the 1950–1989 share and high on the 1960–1979 share, such as Hawaii, Louisiana or Connecticut, has a stock concentrated in the window where all three products overlap.
Ten states hold 54.2 percent of every era-built home in the country.
The evidence ladder, rung by rung
Everything on this page sits on one of four rungs, and we have kept them apart deliberately. A claim high on this ladder can be quoted as fact; one low on it cannot.
The 67,068,006 and every state figure. Published by the Census Bureau with a margin of error. Quotable as fact, within its margin. ACS 2023 5-year, table B25034
The 55× aluminum result and the 1965-to-mid-1970s installation window. A federal agency’s own published conclusion. Quotable, with its scope: outlets only, pre-1972 homes only. CPSC Publication 516, June 2011
The FPE investigation closed with no determination either way. Quotable only as the absence it is — never as clearance, never as condemnation. CPSC news release, 1983
The carrier guidelines. Evidence of what the market does, not of what is dangerous. Quotable about insurance, never about physics. Carrier underwriting guides, retrieved 5 September 2026
What a homeowner can actually establish, in order
The manufacturer’s name is printed on the panel cover or on the label inside the door — Federal Pacific, FPE, Stab-Lok, Zinsco, Sylvania, Challenger. Reading a label is the whole of the safe DIY step.
Do not remove the dead front cover. The bus bars behind it are live even with the main breaker off, and this is the point at which unqualified people are killed.
CPSC’s own instruction: in an unfinished basement, attic or garage, look at the printed or embossed marking on the outer jacket of the cable, using a torch at a low angle.
Aluminum conductors are marked “AL” or “ALUMINUM” every few feet. A marking that also says “CU-clad” or “copper-clad” is a different product and is outside CPSC’s repair recommendations.
The county assessor’s parcel record carries the year built and is the figure your insurer’s data vendor is most likely using. If it is between 1965 and the mid 1970s, the aluminum question is live even if the panel is a modern replacement, because rewiring a panel does not change what is in the walls.
The remedies differ and they are not interchangeable. One of the carriers quoted above will accept aluminum wiring that has been pigtailed with proof from a licensed electrician; the other lists it as ineligible with no route back.
That difference is worth thousands of pounds of work and it is knowable before you commission any of it.
For aluminum branch circuits, CPSC recognizes three permanent repairs and only three: full replacement with copper, COPALUM pigtailing, and AlumiConn connectors. Ordinary twist-on wire connectors are not among them.
For a panel, replacement by a licensed electrician under permit is the work — and the permit matters, because an unpermitted panel swap is the thing the next inspection finds.
Limitations
This is stated at the top of the page and repeated here because it is the limitation that matters more than all the others together.
The count is of homes built when these products were sold. Most of them never had one. Of those that did, many have been replaced. No number here is a panel count.
CPSC dates residential aluminum branch wiring from 1965 to the mid 1970s. Table B25034 divides the stock into decades, so the closest available window is 1960–1979, which is roughly twice as wide as the era itself.
The 34.7 million figure is therefore a substantial overstatement of the aluminum-era stock and is published as an upper bound, not an estimate.
ACS 2023 5-year data pools 2019 through 2023. It is not a 2023 snapshot, and in a fast-building state the pooled estimate lags the current stock.
Census dates mobile homes, houseboats and RVs by the manufacturer’s model year. In states with a large manufactured-housing share, a different quantity is being counted in the same column — and manufactured housing of that era has its own distinct electrical history that this measure does not separate.
The table counts units standing at the time of interview. A home built in 1968, rewired in 2005 and re-panelled in 2018 is counted identically to one that has never been touched. There is no national record of panel replacement, which is precisely why the exposure cannot be narrowed below the era.
Underwriting guidelines are usually confidential. Two were publicly retrievable in full, both Texas programs, and they are quoted rather than characterized. They show the rule exists and what it says. They do not support any claim about what share of the market applies it, and we make none.
Unlike aluminum wiring, which has a CPSC publication, and unlike FPE, which has a closed CPSC investigation, Zinsco has neither. The section above says so rather than borrowing FPE’s federal record to cover it.
Method
Source. US Census Bureau, American Community Survey 2023 five-year estimates, table B25034 (year structure built), for the United States and for each of the 50 states and the District of Columbia. Retrieved 5 September 2026.
Retrieval route. An unauthenticated request to api.census.gov returned a missing-key page on the retrieval date, so figures were taken from the public table-based Summary File at www2.census.gov — the same estimates, published by the same program, from a route requiring no credential.
The substitution changes no figure and is recorded because an unrecorded workaround is how a source quietly stops being checked.
Derivation. The 1950–1989 count is B25034 lines 006 through 009 summed (1980–1989, 1970–1979, 1960–1969, 1950–1959). The 1960–1979 count is lines 007 and 008.
Margins of error on both sums are the square root of the sum of the squared component margins, which is the method the Census Bureau publishes for derived sums, at 90 percent confidence. Percentages are the sum over line 001.
Puerto Rico is excluded throughout; it is in the source file and is not a state.
Evidence for the hazards is CPSC’s own material: Publication 516 (June 2011) for aluminum branch circuits, and the Commission’s 1983 news release for the closure of the Federal Pacific investigation. Both are quoted directly. Carrier positions are quoted from the carriers’ own published underwriting guidelines, named and dated where the document carries a date.
Reproducibility. Every input is a public file. The Summary File for table B25034 is a single download; the state rows are the records whose geographic identifier begins 0400000US. Anyone with the file can rebuild every column in this study, and we would rather they did than take the arithmetic on trust.
Questions
How many US homes have Federal Pacific panels?
Were Federal Pacific Stab-Lok breakers ever recalled?
Which years did homes get aluminum wiring?
How much more likely is aluminum wiring to overheat?
Will insurance actually be refused over an old panel?
Which states have the most homes from this era?
Can I check the panel myself?
What repairs does CPSC actually accept for aluminum wiring?
Does a newer panel mean the aluminum problem is solved?
Written and audited by
HyreElectrical Research Desk
Primary-source research and fact checking
We read the model code, the federal safety notice, the municipal fee sheet or the utility tariff ourselves, and we publish the figure with the document it came from and the date we retrieved it.
Where a number cannot be traced to a primary source, we publish the shorter page and say what we could not verify. HyreElectrical does not perform, supervise or warrant electrical work. Authorship is organizational: this desk, not a named persona.
- 16
- original research studies published
- 5
- states with verified license records
- 16,369
- electrical companies in those records
- 74%
- of the store is Florida — disclosed first, not footnoted
How this desk works
- Primary sources only. Code statements come from NFPA 70 as the model code. Safety statements come from CPSC. Permit fees come from the city or county fee sheet. Utility charges come from the filed tariff. We do not cite a blog that cites a source; we open the source.
- Our contractor store is five states, and 74% of it is Florida. Any figure built on that store is titled to those states and names the concentration in the first screen. It is not a national sample of electricians.
- Load calculations on this site are a published simplification in the shape of NEC 220.82 — first 10 kVA at 100%, remainder at 40%, HVAC at 100%, EVSE at 125%. They are labeled as not a stamped calculation. A licensed electrician using the adopted edition does that work.
- No national price for a panel upgrade is shipped. Labor rates, the adopted code edition, whether the utility is involved, and the state of the existing wiring move the invoice too far for a roundup to help. The cost pages publish named permit fees and the variables that move the price instead.
- We do not perform electrical work, and we take no payment for placement, ranking or a favorable mention. Nobody buys a position on this site.
Data as of 5 September 2026. Authorship on this site is organizational: the analysis belongs to the desk rather than to a named individual, and we do not publish credentials we do not hold. Our editorial policy sets out how we source, date and correct what we publish.
Sources & retrieval dates
Found one of these in your panel?
The next step is a licensed electrician who will pull a permit, not a stranger with an opinion. Tell us what the label says and where the house is, and we will connect you with licensed electrical companies in your area.
HyreElectrical does not perform, supervise or warrant electrical work, and takes no payment for placement, ranking or favorable mention.
This page is research, not advice on a specific property, and nothing on it is a substitute for an inspection by a licensed electrician.
We have no commercial relationship with any insurer, panel manufacturer or connector manufacturer named above.