ASTM B803/B803M-22

Standard Specification for High-Strength Zinc–5 % Aluminum-Mischmetal Alloy-Coated Steel Core Wire for Use in Overhead Electrical Conductors

ABSTRACT
This specification covers round, high-strength, zinc-aluminum-mischmetal (Zn-5Al-MM) alloy-coated, steel core wire with Class A Zn-5Al-MM alloy coating used for mechanical reinforcement in the manufacture of special aluminum and aluminum-alloy conductors, steel reinforced. The base metal shall be steel produced by the open-hearth, electric furnace, or basic oxygen process. The wire shall be cold drawn and coated with Zn-5Al-MM alloy to produce the desired properties. Chemical requirements of the steel, such as carbon, manganese, phosphorus, sulfur, and silicon shall meet the requirements prescribed in this specification. The Zn-5Al-MM-coated steel core wire shall conform to the tensile and elongation requirements. Test methods for tensile, wrap, coating and adherence shall be also be performed.
SCOPE
1.1 This specification covers round, high strength, zinc–5 % aluminum-mischmetal (Zn–5Al–MM) alloy-coated, steel core wire with one class of Zn–5Al–MM coating (MA3) for use in overhead electrical conductors.  
1.2 This specification covers wire of diameter from 0.0500 in. to 0.1900 in. inclusive or 1.27 mm to 4.82 mm inclusive.  
1.3 The values stated in either SI units or inch-pound units are to be regarded separately as standard. The values stated in each system may not be exact equivalents; therefore, each system shall be used independently of the other. Combining values from the two systems may result in non-conformance with the standard.  
1.4 This international standard was developed in accordance with internationally recognized principles on standardization established in the Decision on Principles for the Development of International Standards, Guides and Recommendations issued by the World Trade Organization Technical Barriers to Trade (TBT) Committee.

General Information

• Status: Published
• Publication Date: 30-Sep-2022
• ICS: 77.140.65 - Steel wire, wire ropes and link chains
• Technical Committee: B01 - Electrical Conductors
• Drafting Committee: B01.05 - Conductors of Ferrous Metals

Relations

• Refers: ASTM A370-24 - Standard Test Methods and Definitions for Mechanical Testing of Steel Products
• Effective Date: 01-Mar-2024
• Refers: ASTM A370-19 - Standard Test Methods and Definitions for Mechanical Testing of Steel Products
• Effective Date: 01-Jul-2019
• Refers: ASTM A370-17a - Standard Test Methods and Definitions for Mechanical Testing of Steel Products
• Effective Date: 15-Nov-2017
• Refers: ASTM A370-17 - Standard Test Methods and Definitions for Mechanical Testing of Steel Products
• Effective Date: 01-Jan-2017
• Refers: ASTM B193-16 - Standard Test Method for Resistivity of Electrical Conductor Materials
• Effective Date: 01-Apr-2016
• Refers: ASTM A370-15 - Standard Test Methods and Definitions for Mechanical Testing of Steel Products
• Effective Date: 01-Nov-2015
• Refers: ASTM A370-14 - Standard Test Methods and Definitions for Mechanical Testing of Steel Products
• Effective Date: 15-May-2014
• Refers: ASTM B193-02(2014) - Standard Test Method for Resistivity of Electrical Conductor Materials
• Effective Date: 01-Apr-2014
• Refers: ASTM A751-14 - Standard Test Methods, Practices, and Terminology for Chemical Analysis of Steel Products
• Effective Date: 01-Mar-2014
• Refers: ASTM A370-13 - Standard Test Methods and Definitions for Mechanical Testing of Steel Products
• Effective Date: 15-Nov-2013
• Refers: ASTM A370-12a - Standard Test Methods and Definitions for Mechanical Testing of Steel Products
• Effective Date: 15-Oct-2012
• Refers: ASTM B750-12 - Standard Specification for GALFAN (Zinc-5 % Aluminum-Mischmetal) Alloy in Ingot Form for Hot-Dip Coatings
• Effective Date: 01-May-2012
• Refers: ASTM A370-12 - Standard Test Methods and Definitions for Mechanical Testing of Steel Products
• Effective Date: 15-Mar-2012
• Refers: ASTM A370-11a - Standard Test Methods and Definitions for Mechanical Testing of Steel Products
• Effective Date: 15-Nov-2011
• Refers: ASTM A370-10 - Standard Test Methods and Definitions for Mechanical Testing of Steel Products
• Effective Date: 15-Jun-2010

Overview

ASTM B803/B803M-22: Standard Specification for High-Strength Zinc–5% Aluminum-Mischmetal Alloy-Coated Steel Core Wire for Use in Overhead Electrical Conductors establishes the requirements for manufacturing, testing, and quality assurance of round, high-strength steel core wires coated with a zinc–5% aluminum–mischmetal (Zn–5Al–MM) alloy. These specialized steel wires are designed for mechanical reinforcement in special aluminum and aluminum-alloy conductors, steel reinforced (ACSR), primarily for use in overhead electrical transmission and distribution systems. The standard defines suitable diameters, chemical composition requirements, mechanical properties, and standardized test methods, thereby ensuring consistent performance and interoperability in power utility applications.

Key Topics

• Material requirements: Specifies the use of steel produced by open-hearth, electric furnace, or basic oxygen processes, with strict limits on carbon, manganese, phosphorus, sulfur, and silicon content.
• Alloy coating: Requires the application of a Class A Zn–5Al–MM alloy coating, adhering to thickness and adhesion standards for corrosion protection and mechanical performance.
• Diameter Range: Covers wire diameters from 0.0500 in. to 0.1900 in. (1.27 mm to 4.82 mm).
• Mechanical properties: Details minimum tensile strength, elongation, and stress-at-extension for each diameter range, ensuring wire suitability for high-strength electrical conductor cores.
• Testing and inspection: Includes procedures and acceptance criteria for tensile, wrap, coating weight (A90/A90M), and adherence tests. Specifies sampling rates and retesting protocols to ensure product reliability.
• Permissible variations: Defines acceptable tolerances in wire diameter, taking into account surface irregularities inherent in hot-dip coating processes.
• Ordering and packaging: Outlines the information to be included with procurement, such as wire size, certification requirements, and packaging specifications, to ensure clear communication between manufacturers and purchasers.

Applications

High-strength Zn-5% Al-Mischmetal alloy-coated steel core wire produced under ASTM B803/B803M is primarily used for:

• Overhead electrical conductors: Serving as the core reinforcement in aluminum conductor, steel reinforced (ACSR) cables for transmission and distribution lines.
• Power utility infrastructure: Supporting long-span installations requiring enhanced mechanical strength, corrosion resistance, and longevity.
• Harsh environments: Offering improved durability and coating performance in regions with aggressive atmospheric conditions, reducing maintenance needs and extending service life.
• Specialty conductors: Used in the manufacture of custom or high-performance conductor assemblies where both high tensile strength and superior corrosion protection are essential.

Related Standards

Organizations involved in specifying, manufacturing, or procuring high-strength coated steel wire for overhead conductors may also reference related ASTM and international standards, including:

• ASTM A90/A90M: Test Method for Weight [Mass] of Coating on Iron and Steel Articles with Zinc or Zinc-Alloy Coatings.
• ASTM A370: Test Methods and Definitions for Mechanical Testing of Steel Products.
• ASTM B750: Specification for GALFAN (Zinc-5% Aluminum-Mischmetal) Alloy in Ingot Form for Hot-Dip Coatings.
• ASTM B193: Test Method for Resistivity of Electrical Conductor Materials.
• ASTM A751: Test Methods and Practices for Chemical Analysis of Steel Products.
• ASTM E1277: Test Method for Analysis of Zinc-5% Aluminum-Mischmetal Alloys by ICP Emission Spectrometry.
• GF-1: Practice for Determination of Cerium and Lanthanum Composition in Galfan Alloy.

Practical Value

Adherence to ASTM B803/B803M-22 provides assurance of quality, mechanical integrity, and corrosion resistance vital for reliable operation of overhead power lines. Using standardized Zn–5Al–MM alloy-coated steel core wire enhances conductor performance, reduces life-cycle costs, and supports robust infrastructure in diverse utility environments. This promotes safety, service continuity, and regulatory compliance for manufacturers, power utilities, and stakeholders across the electrical transmission sector.

Standards Content (Sample)

This international standard was developed in accordance with internationally recognized principles on standardization established in the Decision on Principles for the
Development of International Standards, Guides and Recommendations issued by the World Trade Organization Technical Barriers to Trade (TBT) Committee.
Designation:B803/B803M −22
Standard Specification for
High-Strength Zinc–5% Aluminum-Mischmetal Alloy-Coated
Steel Core Wire for Use in Overhead Electrical Conductors
This standard is issued under the fixed designation B803/B803M; the number immediately following the designation indicates the year
of original adoption or, in the case of revision, the year of last revision. A number in parentheses indicates the year of last reapproval.
A superscript epsilon (´) indicates an editorial change since the last revision or reapproval.
1. Scope B193 Test Method for Resistivity of Electrical Conductor
Materials
1.1 This specification covers round, high strength, zinc–5 %
B750 Specification for GALFAN (Zinc-5 % Aluminum-
aluminum-mischmetal (Zn–5Al–MM) alloy-coated, steel core
Mischmetal) Alloy in Ingot Form for Hot-Dip Coatings
wire with one class of Zn–5Al–MM coating (MA3) for use in
E47 Test Methods for Chemical Analysis of Zinc Die-
overhead electrical conductors.
Casting Alloys (Withdrawn 1997)
1.2 This specification covers wire of diameter from
E1277 Test Method for Analysis of Zinc-5 % Aluminum-
0.0500 in. to 0.1900 in. inclusive or 1.27 mm to 4.82 mm
Mischmetal Alloys by ICP Emission Spectrometry
inclusive.
E29 Practice for Using Significant Digits in Test Data to
Determine Conformance with Specifications
1.3 The values stated in either SI units or inch-pound units
are to be regarded separately as standard. The values stated in 2.3 Other Standard:
each system may not be exact equivalents; therefore, each GF-1 Standard Practice for Determination of Cerium and
system shall be used independently of the other. Combining Lanthanum Compositions in GalfanAlloy (5 %Al-0.04 %
values from the two systems may result in non-conformance La-0.04 % Ce-Bal SHG Zn)
with the standard.
3. Terminology
1.4 This international standard was developed in accor-
3.1 Abbreviations:
dance with internationally recognized principles on standard-
3.1.1 MM—mischmetal
ization established in the Decision on Principles for the
Development of International Standards, Guides and Recom-
3.1.2 Zn–5Al–MM—zinc–5 % aluminum mischmetal alloy
mendations issued by the World Trade Organization Technical
3.2 Definitions:
Barriers to Trade (TBT) Committee.
3.2.1 lot—unless otherwise specified in the contract or
order, a lot shall consist of all coils of wire of the same
2. Referenced Documents
diameter and unit lengths submitted for inspection at the same
2.1 The following documents of the issue in effect on date
time.
of material purchase form a part of this specification to the
3.2.2 product code—defines product coating type, coating
extent referenced herein.
class and strength grade; this specification covers only High
2.2 ASTM Standards:
StrengthClassA Zn–5Al–MMcoatedproductsandidentifiedas
A90/A90M Test Method for Weight [Mass] of Coating on
product code MA3.
Iron and Steel Articles with Zinc or Zinc-Alloy Coatings
A370 Test Methods and Definitions for Mechanical Testing
4. Ordering Information
of Steel Products
4.1 Orders for material under this specification shall include
A751 Test Methods and Practices for Chemical Analysis of
the following information:
Steel Products
4.1.1 Quantity of each size,
4.1.2 Wire diameter in inches or millimeters (Section 13),
This specification is under the jurisdiction of ASTM Committee B01 on
4.1.3 Certification, if required (Section 18),
Electrical Conductors and is the direct responsibility of Subcommittee B01.05 on
4.1.4 Test report, if required (Section 18),
Conductors of Ferrous Metals.
4.1.5 Package size (Section 19), and
Current edition approved Oct. 1, 2022. Published October 2022. Originally
approved in 1989. Last previous edition approved in 2019 as B803/B803M – 19.
DOI: 10.1520/B0803_B0803M-22.
2 3
For referenced ASTM standards, visit the ASTM website, www.astm.org, or The last approved version of this historical standard is referenced on
contact ASTM Customer Service at [e-mail]. For Annual Book of ASTM www.astm.org.
Standards volume information, refer to the standard’s Document Summary page on Available from International Lead Zinc Research Organization (ILZRO), 1822
the ASTM website. NC Highway 54 East, Suite 120, Durham, NC 27713, http://www.ilzro.org.
Copyright © ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959. United States
B803/B803M−22
TABLE 2 Tensile Requirements
4.1.6 Product code (Paragraph 3.2.2).
4.1.7 Order Example—Five multiple lengths of 12 000 ft Stress at 1 % Ultimate Tensile Elongation in 10
Specified Diameter
Extension, min Strength, min in., min %
each, 0.1327 in. MA3 wire, packaged onto wooden non-
in. ksi ksi
returnable reels, with certified test report.
0.0500 to 0.0899, incl 210 235 3.0
0.0900 to 0.1199, incl 205 230 3.0
5. Materials and Manufacture
0.1200 to 0.1399, incl 200 225 3.5
0.1400 to 0.1900, incl 195 220 3.5
5.1 The base metal shall be steel produced by the open-
hearth, electric furnace, or basic oxygen process.
5.2 The wire shall be cold drawn and coated with
TABLE 3 Tensile Requirements [Metric]
Zn–5Al–MM alloy to produce the desired properties.
Stress at 1 % Ultimate Tensile Elongation in 250
Specified Diameter
Extension, min Strength, min mm, min %
6. Chemical Composition
mm MPa MPa
6.1 The steel shall conform to the requirements prescribed
1.27 to 2.28, incl 1450 1620 3.0
2.29 to 3.04, incl 1410 1590 3.0
in Table 1.
3.05 to 3.55, incl 1380 1550 3.5
6.2 Chemical analysis of the steel shall be conducted in
3.56 to 4.82, incl 1340 1520 3.5
accordance with Test Methods and Practices A751.
6.3 The ingot form of zinc-5 % aluminum-mischmetal alloy
TABLE 4 Initial Settings for Determining Stress at 1% Extension
shall conform to Specification B750.
Specified Diameter Initial Stress Initial Setting of Extensometer,
6.3.1 For a two-step coating operation where the first
in. ksi in./in.
coating is zinc (hot-dip galvanized or electrogalvanized), the
0.0500 to 0.0899, incl 15 0.0005 (0.05 % Extension)
0.0900 to 0.1199, incl 30 0.0010 (0.10 % Extension)
final bath may have an aluminum content of up to 7.2 %, to
0.1200 to 0.1900, incl 46 0.0015 (0.15 % Extension)
prevent depletion of the aluminum content of the bath.
6.3.2 Method of Analysis—The determination of chemical
composition shall be made in accordance with suitable chemi-
TABLE 5 Initial Settings for Determining Stress at 1% Extension
cal (Test Methods E47 for Tin), ICP Argon Plasma Spectro-
[Metric]
metric (Practice E1277), or other methods. In case of dispute,
Specified Diameter Initial Stress Initial Setting of Extensometer,
the results secured by Practice E1277 shall be the basis of
mm MPa mm/mm
1.27 to 2.28, incl 110 0.0005 (0.05 % Extension)
acceptance.
2.29 to 3.04, incl 210 0.0010 (0.10 % Extension)
6.3.3 A Method of Coating Material Analysis—Refer to
3.05 to 4.82, incl 320 0.0015 (0.15 % Extension)
Specification B750. In case of dispute, the results secured by
Practice E1277 shall be the basis of acceptance.
7. Tensile Test
shall be performed by drawing between wood blocks or by
some other equally satisfactory means.
7.1 The Zn–5Al–MM alloy-coated steel core wire shall
conform to the tensile and elongation requirements prescribed
8. Wrap Test
in Table 2 or Table 3 and a minimum breaking strength (lb [N])
calculated from the minimum required tensile and nominal 8.1 The material, as represented by the test specimens, shall
wire diameter. The wire tensile strength used to determine not fracture when the Zn–5Al–MM alloy-coated wire is
compliance to Table 2 or Table 3 shall be calculated using the wrapped at a rate not exceeding 15 turns/min in a helix of at
actual wire breaking strength and the nominal finished diam- least eight turns around a cylindrical mandrel with a diameter
eter of the wire. equal to three times the specified diameter of the wire under
test, 65 %. The edge-to-edge spacing of consecutive turns
7.2 Tensile tests shall be conducted in accordance with Test
shall not exceed two times the diameter of the wire.
Methods and Definitions A370, using the initial settings for
determining stress at 1 % extension given in Table 4 or Table
9. Coating Test
5 of this specification.
9.1 TheZn–5Al–MMalloy-coatedwireshallconformtothe
7.3 Test Specimens—The test specimens shall be free of
coating requirements prescribed in Table 6 or Table 7.
bendsorkinksotherthanthecurvatureresultingfromtheusual
9.2 The coating test shall be conducted in accordance with
coiling operations.Any hand straightening necessary to permit
Test Method A90/A90M.
insertion of the specimen in the jaws of the testing machine
10. Adherence of Coating Test
TABLE 1 Chemical Requirements
10.1 TheZn–5Al–MMalloy-coatedwireshallbecapableof
Element Composition, %
being wrapped in a close helix at a rate not exceeding
Carbon 0.50 to 0.88
Manganese 0.50 to 1.30 15 turns⁄minaroundacylindricalmandrelhavingadiameteras
Phosphorus, max 0.035
prescribedinTable8orTable9,withoutcrackingorflakingthe
Sulfur, max 0.045
coating to such an extent that any Zn–5Al–MM alloy can be
Silicon 0.10 to 0.35
removed by rubbing with the bare fingers.
B803/B803M−22
TABLE 6 Zn–5Al–MM Alloy Coating
12. Density and Resistivity
Specified Diameter of Area Density of Zn–5Al–MM Alloy Coating min of
12.1 For the purpose of calculating mass per unit length,
Coated Wire Uncoated Wire Surface, oz/ft
cross sections, and so forth, the density of Zn–5Al–MM
in. Class A
alloy-coated steel wire at 20 °C shall be taken as 0.281 lb/in.
0.0500 to 0.0599, incl 0.60
[7780
...

This document is not an ASTM standard and is intended only to provide the user of an ASTM standard an indication of what changes have been made to the previous version. Because
it may not be technically possible to adequately depict all changes accurately, ASTM recommends that users consult prior editions as appropriate. In all cases only the current version
of the standard as published by ASTM is to be considered the official document.
Designation: B803/B803M − 19 B803/B803M − 22
Standard Specification for
High-Strength Zinc–5 % Aluminum-Mischmetal Alloy-Coated
Steel Core Wire for Use in Overhead Electrical Conductors
This standard is issued under the fixed designation B803/B803M; the number immediately following the designation indicates the year
of original adoption or, in the case of revision, the year of last revision. A number in parentheses indicates the year of last reapproval.
A superscript epsilon (´) indicates an editorial change since the last revision or reapproval.
1. Scope
1.1 This specification covers round, high strength, zinc–5 % aluminum-mischmetal (Zn–5Al–MM) alloy-coated, steel core wire
with one class of Zn–5Al–MM coating (MA3) for use in overhead electrical conductors.
1.2 This specification covers wire of diameter from 0.05000.0500 in. to 0.1900 in. 0.1900 in. inclusive or 1.271.27 mm to 4.82
mm 4.82 mm inclusive.
1.3 The values stated in either SI units or inch-pound units are to be regarded separately as standard. The values stated in each
system may not be exact equivalents; therefore, each system shall be used independently of the other. Combining values from the
two systems may result in non-conformance with the standard.
1.4 This international standard was developed in accordance with internationally recognized principles on standardization
established in the Decision on Principles for the Development of International Standards, Guides and Recommendations issued
by the World Trade Organization Technical Barriers to Trade (TBT) Committee.
2. Referenced Documents
2.1 The following documents of the issue in effect on date of material purchase form a part of this specification to the extent
referenced herein.
2.2 ASTM Standards:
A90/A90M Test Method for Weight [Mass] of Coating on Iron and Steel Articles with Zinc or Zinc-Alloy Coatings
A370 Test Methods and Definitions for Mechanical Testing of Steel Products
A751 Test Methods and Practices for Chemical Analysis of Steel Products
B193 Test Method for Resistivity of Electrical Conductor Materials
B750 Specification for GALFAN (Zinc-5 % Aluminum-Mischmetal) Alloy in Ingot Form for Hot-Dip Coatings
E47 Test Methods for Chemical Analysis of Zinc Die-Casting Alloys (Withdrawn 1997)
E1277 Test Method for Analysis of Zinc-5 % Aluminum-Mischmetal Alloys by ICP Emission Spectrometry
E29 Practice for Using Significant Digits in Test Data to Determine Conformance with Specifications
This specification is under the jurisdiction of ASTM Committee B01 on Electrical Conductors and is the direct responsibility of Subcommittee B01.05 on Conductors
of Ferrous Metals.
Current edition approved March 1, 2019Oct. 1, 2022. Published April 2019October 2022. Originally approved in 1989. Last previous edition approved in 20162019 as
B803/B803M – 08 (2016).B803/B803M – 19. DOI: 10.1520/B0803_B0803M-19.10.1520/B0803_B0803M-22.
For referenced ASTM standards, visit the ASTM website, www.astm.org, or contact ASTM Customer Service at [e-mail]. For Annual Book of ASTM Standards
volume information, refer to the standard’s Document Summary page on the ASTM website.
The last approved version of this historical standard is referenced on www.astm.org.
Copyright © ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959. United States
B803/B803M − 22
2.3 Other Standard:
GF-1 Standard Practice for Determination of Cerium and Lanthanum Compositions in Galfan Alloy (5 % Al-0.04 % La-0.04 %
Ce-Bal SHG Zn)
3. Terminology
3.1 Abbreviations:
3.1.1 MM—mischmetal
3.1.2 Zn–5Al–MM—zinc–5 % aluminum mischmetal alloy
3.2 Definitions:
3.2.1 lot—unless otherwise specified in the contract or order, a lot shall consist of all coils of wire of the same diameter and unit
lengths submitted for inspection at the same time.
3.2.2 product code—Definesdefines product coating type, coating class and strength grade. Thisgrade; this specification covers
only High Strength Class A Zn–5Al–MM coated products and identified as product code MA3.
4. Ordering Information
4.1 Orders for material under this specification shall include the following information:
4.1.1 Quantity of each size,
4.1.2 Wire diameter in inches or millimeters (Section 13),
4.1.3 Certification, if required (Section 18),
4.1.4 Test report, if required (Section 18), and
4.1.5 Package Sizesize (Section 19).), and
4.1.6 Product Codecode (Paragraph 3.2.2).
4.1.7 Order Example—Order Example: five Five multiple lengths of 12 000 ft.ft each, 0.1327 in. MA3 wire, packaged onto
wooden non-returnable reels, with certified test report.
5. Materials and Manufacture
5.1 The base metal shall be steel produced by the open-hearth, electric furnace, or basic oxygen process.
5.2 The wire shall be cold drawn and coated with Zn–5Al–MM alloy to produce the desired properties.
6. Chemical Composition
6.1 The steel shall conform to the requirements prescribed in Table 1.
TABLE 1 Chemical Requirements
Element Composition, %
Carbon 0.50 to 0.88
Manganese 0.50 to 1.30
Phosphorus, max 0.035
Sulfur, max 0.045
Silicon 0.10 to 0.35
Available from International Lead Zinc Research Organization (ILZRO), 1822 NC Highway 54 East, Suite 120, Durham, NC 27713, http://www.ilzro.org.
B803/B803M − 22
6.2 Chemical analysis of the steel shall be conducted in accordance with Test Methods, Practices, Methods and Terminology-
Practices A751.
6.3 The ingot form of zinc-5 % aluminum-mischmetal alloy shall conform to Specification B750.
6.3.1 For a two-step coating operation where the first coating is zinc (hot-dip galvanized or electrogalvanized), the final bath may
have an aluminum content of up to 7.2 %, to prevent depletion of the aluminum content of the bath.
6.3.2 Method of Analysis—The determination of chemical composition shall be made in accordance with suitable chemical (Test
Methods E47 for Tin), ICP Argon Plasma Spectrometric (Practice E1277), or other methods. In case of dispute, the results secured
by Practice E1277 shall be the basis of acceptance.
6.3.3 A Method of Coating Material Analysis—Refer to Specification B750. In case of dispute, the results secured by Practice
E1277 shall be the basis of acceptance.
7. Tensile Test
7.1 The Zn–5Al–MM alloy-coated steel core wire shall conform to the tensile and elongation requirements prescribed in Table
2 or Table 3 and a minimum breaking strength (lbs(lb [N]) calculated from the minimum required tensile and nominal wire
diameter. The wire tensile strength used to determine compliance to Table 2 or Table 3 shall be calculated using the actual wire
breaking strength and the nominal finished diameter of the wire.
7.2 Tensile tests shall be conducted in accordance with Test Methods and Definitions A370, using the initial settings for
determining stress at 1 % extension given in Table 4 or Table 5 of this specification.
7.3 Test Specimens—The test specimens shall be free of bends or kinks other than the curvature resulting from the usual coiling
operations. Any hand straightening necessary to permit insertion of the specimen in the jaws of the testing machine shall be
performed by drawing between wood blocks or by some other equally satisfactory means.
8. Wrap Test
8.1 The material, as represented by the test specimens, shall not fracture when the Zn–5Al–MM alloy-coated wire is wrapped at
a rate not exceeding 15 turns/min in a close helix of at least eight turns around a cylindrical mandrel with a diameter equal to three
times the specified diameter of the wire under test, 65 %. The edge-to-edge spacing of consecutive turns shall not exceed two
times the diameter of the wire.
9. Coating Test
9.1 The Zn–5Al–MM alloy-coated wire shall conform to the coating requirements prescribed in Table 6 or Table 7.
9.2 The coating test shall be conducted in accordance with Test Method A90/A90M.
10. Adherence of Coating Test
10.1 The Zn–5Al–MM alloy-coated wire shall be capable of being wrapped in a close helix at a rate not exceeding 1515 turns
turns/min ⁄min around a cylindrical mandrel having a diameter as prescribed in Table 8 or Table 9, without cracking or flaking the
coating to such an extent that any Zn–5Al–MM alloy can be removed by rubbing with the bare fingers.
TABLE 2 Tensile Requirements
Stress at 1 % Ultimate Tensile Elongation in 10
Specified Diameter
Extension, min Strength, min in., min %
in. ksi ksi
0.0500 to 0.0899, incl 210 235 3.0
0.0900 to 0.1199, incl 205 230 3.0
0.1200 to 0.1399, incl 200 225 3.5
0.1400 to 0.1900, incl 195 220 3.5
B803/B803M − 22
TABLE 3 Tensile Requirements [Metric]
Stress at 1 % Ultimate Tensile Elongation in 250
Specified Diameter
Extension, min Strength, min mm, min %
mm MPa MPa
1.27 to 2.28, incl 1450 1620 3.0
2.29 to 3.04, incl 1410 1590 3.0
3.05 to 3.55, incl 1380 1550 3.5
3.56 to 4.82, incl 1340 1520 3.5
TABLE 4 Initial Settings for Determining Stress at 1 % Extension
Specified Diameter Initial Stress Initial Setting of Extensometer,
in. ksi in./in.
0.0500 to 0.0899, incl 15 0.0005 (0.05 % Extension)
0.0900 to 0.1199, incl 30 0.0010 (0.10 % Extension)
0.1200 to 0.1900, incl 46 0.0015 (0.15 % Extension)
TABLE 5 Initial Settings for Determining Stress at 1 % Extension
[Metric]
Specified Diameter Initial Stress Initial Setting of Extensometer,
mm MPa mm/mm
1.27 to 2.28, incl 110 0.0005 (0.05 % Extension)
2.29 to 3.04, incl 210 0.0010 (0.10 % Extension)
3.05 to 4.82, incl 320 0.0015 (0.15 % Extension)
TABLE 6 Zn–5Al–MM Alloy Coating
Specified Diameter of Area Density of Zn–5Al–MM Alloy Coating min of
Coated Wire Uncoated Wire Surface, oz/ft
in. Class A
0.0500 to 0.0599, incl 0.60
0.0600 to 0.0749, incl 0.65
0.0750 to 0.0899, incl 0.70
0.0900 to 0.1039, incl 0.75
0.1040
...