BIS Certification for Welding Cables – IS 9857:1990

Introduction

Welding cables are flexible electrical cables specially designed for carrying current between welding equipment and the welding electrode or workpiece. They are required to withstand repeated bending, movement and the electrical and thermal conditions associated with welding operations.

In India, IS 9857:1990 – Welding Cables – Specification (First Revision) specifies requirements and test methods for single-core flexible cables used in welding circuits. BIS's Product Manual confirms that certification under this standard is operated under Scheme-I of the BIS Conformity Assessment Regulations, 2018.

The standard covers welding cables using copper or aluminium conductors with specified types of coverings. The BIS Product Manual provides requirements for raw materials, sampling, product grouping, testing equipment and inspection and testing.

This guide explains the requirements and certification process for manufacturers seeking BIS certification for Welding Cables as per IS 9857:1990.

About Welding Cables

Welding cables are single-core flexible cables designed for use in welding circuits.

They are generally required to provide:

Electrical conductivity
Flexibility
Mechanical durability
Insulation
Resistance to the operating environment
Suitable current-carrying capability

The BIS Product Manual identifies welding cables with copper (plain/tinned) or aluminium conductors and covering types SE1/SE3 within the certification scope.

What is IS 9857:1990?

IS 9857:1990 is titled:

Welding Cables – Specification (First Revision)

The standard specifies requirements and test methods for single-core flexible cables used in welding circuits. BIS's standards information also identifies IS 9857:1990 as the first revision of the Welding Cables specification.

The BIS Product Manual currently available for this standard identifies one amendment to IS 9857:1990.

Scope of IS 9857:1990

IS 9857:1990 covers single-core flexible cables intended for welding circuits.

The cables are designed for applications where the combination of ambient temperature and load-induced heating results in a steady conductor temperature not exceeding:

60°C for general-service normal-duty elastomeric compound
90°C for heat-resisting, oil-resisting and flame-retardant (HOFR) normal-duty elastomeric compound

These applications and temperature characteristics are identified in BIS's cable standards compendium.

Types of Welding Cables

The BIS Product Manual identifies certification scope based on:

Conductor Material

Plain copper conductor
Tinned copper conductor
Aluminium conductor

Covering

Cable Size

The licence scope is specified according to the applicable conductor material, covering type and cable size.

Manufacturers producing multiple combinations should carefully determine their proposed licence scope before testing.

Applications of Welding Cables

Welding cables are commonly used with:

Arc welding machines
Welding transformers
Welding generators
Welding power sources
Industrial welding equipment
Fabrication equipment
Construction welding equipment
Automotive welding operations
Heavy engineering applications
Shipbuilding and repair
General metal fabrication

The cable must be suitable for the particular welding equipment and operating conditions.

Raw Material Requirements

The BIS Product Manual identifies the following conductor raw materials:

Plain or tinned annealed high-conductivity copper wires
Aluminium wires

The Product Manual references IS 8130 for the applicable conductor requirements.

Manufacturers should maintain proper records for:

Raw-material specifications
Supplier details
Purchase records
Material test certificates
Conductor grade
Batch/lot identification
Traceability

Manufacturing Process

A typical welding cable manufacturing process may include:

1. Conductor Procurement

Suitable copper or aluminium conductor material is selected according to the required product.

2. Wire Drawing

Where applicable, conductor wires are processed to the required dimensions.

3. Annealing

Copper wires may undergo annealing to achieve the required flexibility and electrical characteristics.

4. Stranding

Individual wires are stranded together to form the flexible conductor.

5. Tinning

For tinned copper cables, the conductor wires undergo the applicable tinning process.

6. Insulation/Covering

The appropriate elastomeric covering is applied over the conductor.

7. Extrusion

The covering material is extruded uniformly around the conductor.

8. Cooling

The cable passes through controlled cooling arrangements.

9. Surface Inspection

The finished cable is inspected for surface defects.

10. Electrical and Physical Testing

Samples are tested against the requirements of IS 9857:1990.

11. Length Measurement and Packing

The cable is packed in suitable coils or drums with appropriate identification.

Important Requirements

Conductor

The conductor must comply with the applicable requirements for the selected conductor material.

The use of plain or tinned annealed high-conductivity copper wires or aluminium wires is identified in the BIS Product Manual.

Flexibility

Since welding cables are frequently moved and bent during welding operations, flexibility is an important characteristic.

Electrical Performance

The cable must provide suitable electrical performance under its intended operating conditions.

Insulation/Covering

The covering should provide the required insulation and mechanical protection.

Temperature Performance

The applicable cable type must be suitable for the specified conductor operating temperature.

Testing Requirements

Testing is an important part of BIS certification for Welding Cables.

Depending on the applicable cable type and certification scope, testing can include:

Conductor resistance
Conductor dimensions
Overall dimensions
Electrical tests
Insulation/covering tests
Mechanical tests
Ageing-related tests
Flexibility-related tests
Flame-retardant characteristics where applicable
Marking and identification
Other applicable tests specified by IS 9857:1990

The exact test programme should be checked against the latest applicable standard, Product Manual and Scheme of Inspection and Testing.

BIS Laboratory Testing

BIS LIMS currently lists testing facilities for IS 9857:1990 – Welding Cables – Specification (First Revision).

Current BIS LIMS listings show different laboratory scopes and charges. For example, one listing shows a testing charge of ₹8,500, while another listing shows ₹11,400 for its listed scope.

The final laboratory cost depends on:

Laboratory
Cable type
Conductor material
Cable size
Testing scope
Applicable test parameters

Therefore, the current laboratory quotation should be confirmed before sample submission.

Sample Requirements

The BIS Product Manual specifies the following sample requirements:

Copper/Aluminium Wire Before Stranding

5 metres

Copper Wire for Purity Test

100 grams

Finished Welding Cable

15 metres

These sample quantities are specified in the BIS Product Manual for IS 9857:1990.

Proper sample identification and traceability should be maintained during the certification process.

Product Grouping

The BIS Product Manual contains specific grouping guidelines in Annex A.

Product grouping is important where the manufacturer produces multiple:

Conductor materials
Cable types
Coverings
Sizes

The scope of a BIS licence is determined based on the applicable grouping requirements and test evidence.

Manufacturers should review the grouping requirements before deciding which sizes and variants to include in the initial application.

Testing Equipment

The BIS Product Manual provides a list of testing equipment under Annex B.

Depending on the product scope, the manufacturer may require suitable facilities for:

Electrical resistance testing
Dimensional measurement
Conductor testing
Tensile testing
Elongation testing
Ageing tests
Insulation/covering tests
Flexibility testing
Flame-related testing where applicable
Other specified tests

All applicable measuring and testing equipment should be properly maintained and calibrated.

Factory Inspection

During the BIS factory assessment, important areas can include:

Raw Material Inspection

Verification of conductor material and covering materials.

Manufacturing Process

Inspection of wire processing, stranding, covering and extrusion processes.

Testing Facility

Verification of available testing equipment.

Calibration

Checking calibration certificates and calibration schedules.

Quality Control

Review of incoming, in-process and finished-product testing.

Traceability

Verification of batch, lot and production records.

Finished Product

Inspection of cable dimensions, appearance, marking and other applicable characteristics.

Packing and Marking

Review of product identification and packing arrangements.

Quality Control

Manufacturers should maintain proper controls for:

Incoming raw materials
Conductor dimensions
Conductor resistance
Stranding
Covering thickness
Extrusion parameters
Finished cable dimensions
Electrical performance
Physical properties
Production batches
Testing records
Calibration

A proper quality-control system helps maintain consistency between production batches.

Documents Required

Common documents for BIS certification may include:

Company registration documents
Factory address proof
Factory layout
Manufacturing process flow
Machinery list
Product specifications
Cable drawings
Conductor details
Raw-material specifications
Supplier test certificates
Internal test reports
Testing equipment list
Calibration certificates
Quality-control plan
Inspection records
Product photographs
Packing details
Marking details
Authorized signatory documents
Trademark documents, where applicable

The final documentation depends on the manufacturer's factory and proposed licence scope.

BIS Marking

After BIS licence grant, the manufacturer can use the applicable BIS Standard Mark and licence number (CM/L) according to the certification conditions.

Product identification should clearly communicate the required information applicable to the certified cable.

The Standard Mark should only be used for products covered within the approved BIS licence scope.

BIS Licence Scope

The BIS Product Manual indicates that the licence scope can be described in terms of:

Welding Cables with Copper (Plain/Tinned)/Aluminium Conductor, Type of Covering SE1/SE3, for Sizes up to and including the approved size.

Therefore, manufacturers should carefully define:

Conductor material
Copper type
Covering type
Cable size
Proposed product range

before applying for certification.

Who Needs BIS Certification?

The applicable BIS requirements can affect manufacturers producing Welding Cables covered under IS 9857:1990.

This can include:

Welding cable manufacturers
Electrical cable manufacturers
Flexible cable manufacturers
Welding equipment suppliers manufacturing cables
Industrial cable manufacturers
Electrical product manufacturers
Cable assembly manufacturers where the product falls within the standard's scope

Importers should separately verify the current regulatory requirements applicable to imported Welding Cables.

Eligibility Requirements

A manufacturer should generally have:

Suitable manufacturing premises
Conductor processing facilities
Stranding machinery
Extrusion machinery
Suitable covering compound processing facilities
Measuring equipment
Testing facilities or permitted testing arrangements
Quality-control procedures
Calibration arrangements
Trained technical personnel
Batch traceability

Common Reasons for Certification Delays

Manufacturers may experience delays due to:

Incorrect product classification
Incorrect conductor selection
Incorrect covering type
Incomplete product specifications
Poor raw-material records
Conductor resistance failure
Dimensional non-conformity
Insulation/covering failure
Mechanical test failure
Ageing test failure
Inadequate testing equipment
Missing calibration certificates
Incomplete quality-control records
Improper sample preparation
Factory not ready for inspection
Incorrect product marking

Proper technical preparation before the BIS application can help reduce avoidable delays.

Cost of BIS Certification

The overall cost can depend on:

BIS application charges
Laboratory testing
Number of cable types
Conductor material
Cable sizes
Product grouping
Sample transportation
Factory inspection
Testing equipment
Calibration
Retesting
Documentation
Consultancy charges

Current BIS LIMS listings demonstrate that laboratory charges can vary between laboratories and testing scopes.

Certification Timeline

The certification timeline depends on:

Product scope
Documentation readiness
Factory readiness
Sample preparation
Laboratory availability
Testing duration
BIS application processing
Factory assessment
Test report evaluation
Closure of observations

A realistic timeline can be estimated after reviewing the manufacturer's product range and existing testing facilities.

Benefits of BIS Certification

Compliance with Applicable Requirements

Helps manufacturers meet the applicable requirements for certified Welding Cables.

Product Quality

Testing helps verify electrical, mechanical and physical characteristics.

Customer Confidence

BIS certification provides confidence that the product conforms to the applicable Indian Standard.

Market Acceptance

Certification supports supply where BIS certification is required.

Better Manufacturing Control

Regular inspection and testing help maintain consistent production quality.

Product Traceability

Proper batch and test records improve traceability.

Business Credibility

Certification can strengthen confidence among industrial and commercial customers.

Why Choose Qualitance India?

Qualitance India provides BIS certification consultancy for manufacturers dealing with electrical and industrial products covered by Indian Standards.

For Welding Cables as per IS 9857:1990, assistance can include:

Product applicability assessment
Conductor and covering review
Product scope planning
Product grouping guidance
Documentation support
Testing requirement review
Laboratory coordination
Sample preparation guidance
BIS application assistance
Factory inspection preparation
Quality-control documentation
Test report coordination
Observation closure assistance
BIS licence support

Qualitance India

Phone: +91-9310-615-170
Email: info@qualitanceindia.com
Website: https://qualitanceindia.com/

BIS Certification Process

Product Identification
↓
IS 9857:1990 Requirement Review
↓
Conductor & Covering Identification
↓
Size & Product Scope Assessment
↓
Product Grouping Review
↓
Factory & Testing Facility Assessment
↓
Documentation Preparation
↓
Sample Preparation
↓
Laboratory Testing
↓
BIS Application
↓
BIS Scrutiny
↓
Factory Assessment
↓
Test Report Evaluation
↓
Observation Closure
↓
BIS Licence Grant
↓
BIS Standard Mark

Frequently Asked Questions

1. What is IS 9857:1990?

IS 9857:1990 is the Indian Standard for Welding Cables – Specification (First Revision).

2. What are welding cables used for?

They are single-core flexible cables used in welding circuits.

3. What conductor materials are covered?

The BIS Product Manual identifies plain/tinned annealed high-conductivity copper wires and aluminium wires.

4. What covering types are covered?

The Product Manual identifies SE1 and SE3 covering types within the certification scope.

5. What sample size is required?

The Product Manual specifies 15 metres of finished welding cable, along with specified samples of conductor material where applicable.

6. Is BIS certification available for Welding Cables?

Yes. BIS has a Product Manual for IS 9857:1990 under Scheme-I of the BIS Conformity Assessment Regulations, 2018.

7. Is product grouping applicable?

Yes. The Product Manual contains grouping guidelines in Annex A.

8. What tests are performed on Welding Cables?

Testing depends on the applicable product scope and can include electrical, dimensional, mechanical and covering-related tests.

9. Is conductor resistance tested?

Electrical characteristics including conductor-related requirements form part of conformity evaluation.

10. Is flexibility important for welding cables?

Yes. Welding cables are designed for flexible use in welding circuits and must meet the applicable requirements of the standard.

11. What temperature ratings are mentioned for Welding Cables?

BIS's cable standards compendium identifies 60°C for general-service normal-duty elastomeric compound and 90°C for heat-resisting, oil-resisting and flame-retardant normal-duty elastomeric compound.

12. Is factory inspection required?

Factory assessment forms part of the applicable BIS certification process under Scheme-I.

13. Is testing equipment required at the factory?

The manufacturer needs appropriate testing arrangements according to the applicable certification requirements and product scope.

14. Can multiple sizes be covered in one BIS licence?

Multiple sizes can potentially be covered according to the applicable product grouping and testing requirements.

15. Can copper and aluminium Welding Cables be included together?

The licence scope can depend on the applicable grouping requirements. Each proposed conductor type should be assessed before application.

16. What is the current laboratory testing cost?

Current BIS LIMS listings show different charges depending on the laboratory and scope, including examples of ₹8,500 and ₹11,400.

17. What documents are required?

Factory documents, manufacturing details, product specifications, raw-material information, testing details, calibration records and quality-control documents are commonly required.

18. What causes Welding Cable testing failure?

Common issues can include conductor resistance, dimensions, covering properties, mechanical performance and other applicable test failures.

19. Can Qualitance India help with IS 9857 certification?

Yes. Qualitance India can assist with product assessment, documentation, laboratory coordination, BIS application and factory inspection preparation.

20. How can I start BIS certification for Welding Cables?

You can start by sharing your conductor material, covering type, cable sizes, manufacturing process and factory testing facilities.

Website Image Text

WELDING CABLES

IS 9857:1990

BIS CERTIFICATION CONSULTANCY

Qualitance India

+91-9310-615-170
info@qualitanceindia.com
qualitanceindia.com

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Need BIS Certification for Welding Cables?

If you manufacture Welding Cables covered under IS 9857:1990, proper preparation of the conductor, covering, cable sizes, manufacturing process, testing facilities and quality-control documentation is important.

Qualitance India can assist with product assessment, product grouping, documentation, laboratory coordination, BIS application and factory inspection preparation.

Qualitance India
Phone: +91-9310-615-170
Email: info@qualitanceindia.com
Website: https://qualitanceindia.com/

Contact Qualitance India for assistance with BIS Certification for Welding Cables as per IS 9857:1990.

Conclusion

Welding cables are essential flexible electrical cables used in welding circuits and industrial fabrication applications. IS 9857:1990 specifies requirements and test methods for single-core flexible welding cables and covers applicable conductor and covering configurations.

For BIS certification, manufacturers need to carefully assess their conductor material, covering type, cable sizes, manufacturing process, product grouping, testing facilities and quality-control system.

The BIS Product Manual provides specific guidance on sampling, grouping, testing equipment and inspection and testing requirements.

With proper preparation and technical documentation, manufacturers can make the BIS certification process more systematic and ensure that their Welding Cables comply with the applicable requirements of IS 9857:1990.

Qualitance India can support manufacturers throughout the BIS certification process for Welding Cables as per IS 9857:1990.