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Designation: A 411 – 9803

Standard Specification for

Zinc-Coated (Galvanized) Low-Carbon Steel Armor Wire1
This standard is issued under the fixed designation A 411; 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 (e) indicates an editorial change since the last revision or reapproval.

1. Scope*
1.1 This specification covers zinc-coated low-carbon steel wire for use in armoring for protection against damage of submarine
and underground cables used for communication, control, or power purposes.
1.2 The values stated in inch-pound units are to be regarded as the standard.

1
This specification is under the jurisdiction of ASTM Committee A-5 A05 on Metallic Coated Iron and Steel Products and is the direct responsibility of Subcommittee
A05.12 on Wire Specifications.
Current edition approved April 10, 1998. October 1, 2003. Published November 1998. December 2003. Originally published as A 411 – 57. approved in 1957. Last previous
edition A 411 – 86 (1996). approved in 1998 as A 411 - 98.

*A Summary of Changes section appears at the end of this standard.

Copyright © ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959, United States.

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 A 411 – 9803
2. Referenced Documents
2.1 ASTM Standards: 2
A 90/A 90M Test Method for Weight [Mass] of Coating on Iron and Steel Articles with Zinc or Zinc-Alloy Coatings
A 938 Test Method for Torsion Testing of Wire
B 6 Specification for Zinc (Slab Zinc)
E 8 Test Methods of Tension Testing of Metallic Materials
3. Ordering Information
3.1 OIt shall be the rdesponsibility of the purchaser to specify all requirements that are necessary for armor wire purchased
material under this specification s. Such requirements mally include, but are not limited to, the following information:
3.1.1 Quantity of each size,
3.1.2 Wire size, diameter in inches ( or in [millimetres)] (Section 12), and
3.1.3 Weight [Mass], inside diameter, and method of banding of coils.
4. Zinc for Coating
4.1 The slab zinc used for the coating shall be any grade of zinc conforming to Specification B 6.
5. Base Metal
5.1 The base metal shall be open-hearth, basic-oxygen, or electric-furnace steel, ingot or continuous cast, and of such quality
that, when processed and zinc-coated, the finished wire shall have the properties prescribed in this specification.
6. Joints
6.1 The wire shall be furnished in coils of one continuous length. Welds made prior to final wire drawing shall be permitted.
7. Tensile Strength
7.1 The zinc-coated wire shall have a tensile strength of not less than 50 000 psi ( [345 MPa)], nor more than 70 000 psi ( [483
MPa)]. The tensile strength of the zinc-coated wire shall be determined in accordance with Test Methods E 8. The diameter of the
wire shall be measured over the zinc coating for the purpose of calculating the tensile strength.
8. Elongation
8.1 The zinc-coated wire shall have an elongation of not less than 10 % in 10 in. (254 mm) [254 mm] for nominal sizes 0.284
in. ( [7.21 mm)] and smaller. Nominal sizes larger than 0.284 in. shall have an elongation of not less than 9 % in 10 in. The
elongation shall be determined as the permanent increase in length after failure of a marked section of the wire originally 10 in.
in length.
9. Torsion Test
9.1 The zinc-coated wire shall withstand without fracture the minimum number of twists turns specified in Table 1. This test
shall be made on an initial wire length of 6 in. (152 mm) between jaws of a standard torsion machine, or equivalent, done in
accordance with one head of Test Method A 938 and the machine movable horizontally. The effective speed number of rotation
turns to failure shall not exceed 60 rpm.
9.1.1 An initial wire length longer than 6 in. between jaws may be used and meet the number requirements of twists in Table
1 shall be increased proportionately per unit length. 1.
10. Weight of Coating
10.1 The weight of zinc coating, in ounces per square foot ( or [grams per square metre)] of uncoated wire surface, shall be not
less than that specified in Table 2.
10.2 Weight of Coating Test—The zinc coating shall be tested for weight by a stripping test in accordance with Test Methods
A 90/A 90M.
11. Adherence of Coating
11.1 The zinc coating shall remain adherent when the wire is wrapped at a rate of not more than 15 turns per minute in a close
helix of at least 2 turns around a cylindrical mandrel of the diameter specified in Table 3. The zinc coating shall be considered as
meeting this requirement if, when the wire is wrapped about the specified mandrel, the coating does not flake and none of it can
be removed from the wire by rubbing with fingers. Loosening or detachment during the adhesion test of superficial, small particles
of zinc formed by mechanical polishing of the surface of zinc-coated wire shall not be considered cause for rejection.

2
For referenced ASTM standards, visit the ASTM website, www.astm.org, or contact ASTM Customer Service at [email protected]. For Annual Book of ASTM Standards,
Vols 01.06 and 02.03. volume information, refer to the standard’s Document Summary page on the ASTM website.

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 A 411 – 9803
TABLE 1 Minimum Number of Twisturns
Nominal Wire Minimum
Diameter, Number of
in. (mm) Tw ists
Nominal Wire Minimum
Nominal Wire Diameter, in. [mm] Diameter, Turns
in. (mm) (8 in. gage length)
0.239 (6.07) and over 5
0.239 [6.07] and over 0.239 (6.07) and over 5
0.238 to 0.166 (6.05 to 7
4.22)
0.238 to 0.166 [6.05 to 4.22] 0.238 to 0.166 (6.05 to 7
4.22)
0.165 to 0.110 (4.19 to 10
2.79)
0.165 to 0.110 [4.19 to 2.79] 0.165 to 0.110 (4.19 to 13
2.79)
0.109 to 0.065 (2.77 to 14
1.65)
0.109 to 0.065 [2.77 to 1.65] 0.109 to 0.065 (2.77 to 19
1.65)

TABLE 2 Minimum Weights of Zinc Coating

Size
Nominal Diameter of (Birmingham Minimum Weight of Zinc Coating oz/ft2 (g/m2) of
Coated Wire, in. (mm) Wire Gage) Uncoated Wire Surface
(mm)
Size
Nominal Diameter of (Birmingham Minimum Weight of Zinc Coating oz/ft2[g/m2] of
Coated Wire, in. [mm] Wire Gage) Uncoated Wire Surface
(mm)
0.340 (8.64) 1/0 (8.63) 1.00 (300)
0.340 [8.64] 1.63) 1.00 [300]
0.300 (7.62) 1 (7.62) 1.00 (300)
0.300 [7.62] 1.62) 1.00 [300]
0.284 (7.21) 2 (7.21) 1.00 (300)
0.284 [7.21] 1) 1.00 [300]
0.259 (6.58) 3 (6.58) 1.00 (300)
0.259 [6.58] 3 (6.58) 1.00 [300]
0.238 (6.05) 4 (6.05) 1.00 (300)
0.238 [6.05] 4 (6.05) 1.00 [300]
0.220 (5.59) 5 (5.59) 1.00 (300)
0.220 [5.59] 5 (5.59) 1.00 [300]
0.203 (5.16) 6 (5.16) 1.00 (300)
0.203 [5.16] 16) 1.00 [300]
0.165 (4.19) 8 (4.19) 0.90 (270)
0.165 [4.19] 8 (4.19) 0.90 [270]
0.134 (3.40) 10 (3.40) 0.80 (240)
0.134 [3.40] 0.40) 0.80 [240]
0.109 (2.77) 12 (2.77) 0.80 (240)
0.109 [2.77] 12 (2.77) 0.80 [240]
0.083 (2.11) 14 (2.11) 0.60 (180)
0.083 [2.11] 14 (2.11) 0.60 [180]
0.065 (1.65) 16 (1.65) 0.50 (150)
0.065 [1.65] 16 (1.65) 0.50 [150]

12. Size and Permissible Variations

12.1 Size—The size of the zinc-coated wires shall be expressed as the diameter of the wire in decimal fractions of an inch or
[millimetres].
12.2 Permissible Variations—The permissible variations of the zinc-coated wire from the nominal diameter shall be as specified
in Table 4.
13. Workmanship, Finish and Appearance
13.1 The surface of the wire shall be free from injurious scale, flaws, seams and splits, and other imperfections not consistent
with good commercial practice. The coating shall be continuous and reasonably uniform.
14. Sampling
14.1 The inspector shall select at random one sample coil from every 10 coils in the first 100 coils of the lot, and one sample
for every additional 35 coils but not less than 3 coils from the entire lot. From each coil of zinc-coated wire thus selected, a sample

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 A 411 – 9803
TABLE 3 Mandrel Diameter for Adherence of Coating Tests
Wire Diameters, in. (mm) Mandrel Size
Wire Diameters, in. [mm] Mandrel Size
0.259 (6.58) and over 53
0.259 [6.58] and over 0.259 (6.58) and over 53
0.258 to 0.134 (6.55 to 33
3.40)
0.258 to 0.134 [6.55 to 3.40] 0.258 to 0.134 (6.55 to 33
3.40)
0.133 (3.38) and under 23
0.133 [3.38] and under 23

TABLE 4 Permissible Variations in Diameter of Zinc-Coated Wire

NOTE 1—It is recognized that the surfaces of zinc coatings, particularly

those produced by hot-dip galvanizing, are not perfectly smooth and
devoid of irregularities. If the tolerances shown are rigidly applied to such
irregularities that are inherent to the product, unjustified rejections of wire
that would actually be satisfactory for use could occur. Therefore, it is
intended that these tolerances be used in gaging the uniform areas of the
galvanized wire.
Permissible Variations, plus
Nominal Diameter of Coated Wire, in. (mm)
or minus, in. (mm)
Permissible Variations, plus
Nominal Diameter of Coated Wire, in. [mm]
or minus, in. [mm]
0.340 to 0.260 (8.64 to 6.60) 0.006 (0.15)
0.340 to 0.260 [8.64 to 6.60] 0.006 [0.15]
0.259 to 0.166 (6.58 to 4.22) 0.005 (0.13)
0.259 to 0.166 [6.58 to 4.22] 0.005 [0.13]
0.165 to 0.109 (4.19 to 2.77) 0.004 (0.10)
0.165 to 0.109 [4.19 to 2.77] 0.004 [0.10]
0.108 to 0.065 (2.74 to 1.65) 0.003 (0.08)
0.108 to 0.065 [2.74 to 1.65] 0.003 [0.08]

of suitable length shall be taken for the weight of coating and mechanical tests as specified in Sections 7-11, inclusive.
15. Inspection
15.1 The manufacturer shall afford
15.1 Unless otherwise specified in the inspector representing contract or purchase order, the purchaser all reasonable facilities,
without charge, to satisfy him that the material manufacturer is being furnished responsible for the performance of all inspection
and test requirements specified in accordance with this specification. All tests and inspections shall be made at standard. Except
as otherwise specified in the contract or purchase order, the manufacturer may use his own or any other suitable facility for the
performance of manufacture prior to shipment, the inspection and test requirements unless otherwise agreed upon disapproved by
the purchaser at the time of purchase, and the order is placed. The purchaser shall be so conducted as not to interfere unnecessarily
with have the operation right to perform any of the inspections and tests set forth in this standard when such inspections and tests
arke deemed necessary to assure that the material conforms to prescribed requirements.
16. Rejection
16.1 Failure of any of the test specimens to comply with the requirements of this specification shall constitute grounds for
rejection of the lot represented by the specimen. The lot may be re-submitted for inspection by testing every coil for the
characteristics in which the specimen failed, and sorting out the defective coils.
17. Packaging
17.1 The finished zinc-coated wire shall be furnished in compact coils reasonably symmetrical in shape. The weight, inside
diameter, and method of banding of the coils shall be agreed upon between the manufacturer and the purchaser.
18. Marking
18.1 To each coil
18.1 A durable tag shall be securely attached a durable tag to each coil showing the nominal size of wire and the name or mark
of the manufacturer. The starting end of each coil shall be indicated by a suitable tag.
19. Keywords
19.1 armor wire; zinc coated steel armor wire

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 A 411 – 9803

SUMMARY OF CHANGES

Committee A05 has identified the location of selected changes to this standard since the last issue (A 411 - 98)
that may impact the use of this standard.

A 411 - 03:
(1) Edited paragraph 3.1 for ordering information consistency with all A05 standards.
(2) Added metric characteristics to paragraphs 3.1.2, 3.1.3, 10.1, and 12.1 since metric values are provided in the tables.
(3) Added the casting method to the steelmaking method for clarification in Section 5.
(4) Changed Section 9 for clarity and uniformity between standards.
(5) Changed Section 15 for clarity.
(6) Made an editorial change to the first sentence in paragraph 18.1.
(7) Eliminated Birmingham Wire Gage from Table 2.

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