MIL-DTL-49104C
3.2.2 Steel strands. Steel strands shall be round steel wire .011 in ±0.05 in (.28 mm ±1.27 mm)
diameter. The wire shall be coated with a smooth, continuous, uniform and adherent zinc coating of
commercially pure zinc (galvanized) in accordance with ASTM A641/A641M. The weight of zinc shall not
be less than 25 grams of zinc per kilogram of coated strand.
3.2.3 Insulation compound. The insulation compound shall be black high-density polyethylene or
copolymer, type III, class H, grade 1, in accordance with L-P-390, except that the carbon black content
shall be no greater than 2.5%.
3.2.4 Recycled, recovered, or environmentally preferable materials. Recycled, recovered, or
environmentally preferable materials should be used to the maximum extent possible provided that the
material meets or exceeds the operational and maintenance requirements, and promotes economically
advantageous life-cycle costs.
3.3 Construction.
3.3.1 Conductors. Each conductor shall be composed of four coated copper strands and three
coated steel strands.
3.3.1.1 Stranding. The maximum length of lay of the strand conductor shall be one inch and the
direction of lay shall be left hand. The outside strands shall lie evenly and smoothly around the central
strand without crowding. An antioxidant, such as Liquid Antox manufactured by E.I. duPont deNemours
and Co., Inc.; Bayol 35, manufactured by Humble Oil and Refining Co.; MX-910 lube-oil manufactured by
Mohawk Refining Co.; or an equally satisfactory light oil, may be used as a lubricant in the stranding
operation, in which case there shall be no excess oil on the finished stranded conductor.
3.3.2 Finished cable characteristics. The finished cable shall consist of a pair of conductors in
parallel, commonly insulated in an approximate figure-8 cross section (see figure 1). The finished cable
shall be twisted right-hand-lay (such as in a bunch strander) to make one twist per 12 inches (304.80 mm)
when averaged over a 100-foot length. Separation of the conductors of the pair shall be by snipping the
insulation at the end of the pair midway between the conductors and then tearing them apart. The tensile
force necessary to separate the two conductors shall be not less than 1 pound or more than 3 pounds.
After the conductors are separated, the insulation shall not pull away from either conductor. No insulation
repairs or wire splices shall be permitted in finished cable. The dimensions of the cable shall be as
follows (see figure 1):
.135 ±.005 inch (3.43 ±.13 mm)
A
Major axis
.070 ±.003 inch (1.78 ± .08 mm)
B
Minor axis
.033 ±.003 inch (0.84±.08 mm) (between inside surface of
C
Conductor separation
the conductors)
.033 ±.003 inch (.84 ±. 08 mm)
D
Conductor diameter
3
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