Welding cables are essential for carrying electrical current between the welding machine and the electrode. They are designed to handle high current loads. The cables come with an insulated structure for durability and protection against any form of external damage. Cables are widely applied during industrial work and welding processes. The use of reliable cables helps to ensure safe welding performance.
To ensure the safety requirements, a BIS certification is required for the Welding cables. The cables must possess particular qualities related to conductivity and durability. As per IS 9857: 1990, these cables are tested for electrical conductivity. Manufacturers of cables must obtain a product license to sell the product in the market.
What is IS 9857: 1990?
This is the Indian Standard for the welding cables used in electric welding applications. It mentions the safety and performance criteria for the cables. As per the BIS (Bureau of Indian Standards), cables for welding are:
- Tested for electrical conductivity
- Evaluated for insulation strength
- Checked for flexibility
- Verified for resistance to heat
- Assessed for overall safety
Eligibility for Durable Welding Electrical Cable BIS License
BIS authorisation under IS 9857: 1990 is required for businesses involved in manufacturing, importing, or supplying flexible welding cable in India.
Applicable to:
- Manufacturers (India) - Must get BIS approval if the electrode cables are covered under QCO.
- Foreign Manufacturers - Need certification to export the product to India.
- Importers/Brand Owners - Must ensure that the high-performance welding cables are BIS-certified before sale.
- Sellers/Distributors - Should only sell certified current-carrying welding cables.
Testing and Inspection Requirements
To ensure safe performance of welding cables used in industrial and electrical welding applications, the Bureau of Indian Standards outlines the minimum requirements under IS 9857: 1990. This certification ensures that manufacturers meet the electrical standards for welding cables.
The BIS testing parameters and quality checks for the welding power cable are listed below:
| Test Group | What is Tested | Purpose |
|---|
| Conductor Purity Test | Purity of copper/aluminium conductor material | Ensures high conductivity and efficient current flow |
| Conductor Resistance Test | Electrical resistance of the conductor | Ensures proper current-carrying capacity and minimal power loss |
| High Voltage / Spark Test | Insulation integrity under high voltage | Ensures safety against electrical breakdown and leakage |
| Tensile Strength Test | Mechanical strength of conductor and insulation | Ensures cable can withstand pulling and installation stresses |
| Elongation Test | Flexibility and stretchability of conductor | Ensures flexibility during handling and welding operations |
| Annealing Test | Softness and ductility of copper conductor | Ensures proper flexibility and ease of bending without cracking |
| Thickness of Covering Test | Insulation layer thickness measurement | Ensures adequate insulation and protection from damage |
| Flammability Test | Behaviour of cable under flame exposure | Ensures fire resistance and safe usage in welding environments |
| Oil Resistance Test | Effect of oil exposure on insulation | Ensures durability in industrial environments with oil contact |
| Hot Set / Thermal Ageing Test | Performance of insulation under heat and ageing | Ensures long-term stability under high temperature conditions |
| Flammability & Heat Resistance Check | Behaviour under heat and fire exposure | Ensures operational safety in high-temperature welding conditions |
| Electrical Insulation Resistance Test | Resistance offered by insulation material | Ensures safe separation of electrical current from surroundings |
Steps for Heavy-Duty Welding Cable BIS Approval
The BIS Approval process ensures that the cables meet the required standards for proper and efficient operation. This process is set by the Bureau of Indian Standards (BIS) and includes the following steps:
- Online Registration: Manufacturers register on the BIS Manak portal by submitting company, factory, and product details. Foreign manufacturers must appoint an Authorized Indian Representative (AIR).
- Testing at BIS-Approved Laboratory: Product samples are tested in BIS-approved laboratories for electrical conductivity, current-carrying capacity, insulation resistance, flexibility, and heat resistance.
- Application Submission: The application is submitted along with test reports, technical documents, and factory details. Foreign manufacturers must also submit AIR-related documents.
- Factory Inspection: Officials from the Bureau of Indian Standards inspect the manufacturing units to verify the production process, safety measures, and quality control system.
- Grant of BIS License: After successful verification of all requirements, BIS issues the certification license under Scheme-I.
- Use of ISI Mark: Once approved, the manufacturer is authorized to affix the ISI mark on the product with a CM/L number, confirming that the product meets BIS standards.
Documents Guide for IS 9857: 1990 Approval
| Document Category | Documents Required |
|---|
| Basic Details | GST Certificate, Email ID & Contact Number, Factory & Office Address, Rent Agreement / Lease Deed (if applicable),Partnership Deed (if applicable for partnership firms) |
| Manufacturing Details | List of Machinery, Process Flow Chart, Factory Layout Plan |
| Raw Material Details | List of Raw Materials, Supplier Details, Raw Material Invoices, Raw Material Test Certificates |
| Testing & Quality Control | List of Testing Equipment, Calibration Certificates, QC/Lab In-charge Appointment Letter & Qualification |
| Production Details | Annual Installed Capacity, Last Year Production Value |
| Product & Packaging Details | Quantity per Package, Nature of Packing, Product Printing / Marking Details |
| Management Details | Top Management Details, BIS Communication Contact Person |
| Brand & Certification Documents | Trademark / Brand Certificate, Consent Letter from BIS Recognized Laboratory |
| Additional Documents | Weekly Off Details, Hygiene Document (if applicable), Relaxation Letter (if applicable), Any Other Relevant Document |
| Foreign Manufacturer Requirement | Appointment of Authorized Indian Representative (AIR) for BIS coordination and compliance in India |
Foreign manufacturers are required to appoint an Authorized Indian Representative (AIR) in India. This representative is the local point of contact for the Bureau of Indian Standards (BIS) and ensures all regulatory and compliance requirements are met in India.
Marking Requirements & License Validity
Marking Requirements
Once a manufacturer obtains BIS approval, the ISI Mark for flexible welding cable must be clearly and permanently marked on its packaging or on the product. Along with the ISI Mark, important details such as the manufacturer’s identification and licence number (CM/L) must be written. This ensures the product complies with all safety standards. Further details are mentioned below:
| Requirement | Details |
|---|
| ISI Mark | Indicates that the product is BIS certified and conforms to standards |
| Standard Number | IS 9857: 1990 |
| CML Number | Certification Marks License (CML) number issued by BIS |
| Manufacturer Details | Name of manufacturer or registered trademark |
| Batch / Date | Batch number, heat number, or manufacturing date for traceability |
Note: Marking is typically applied using durable stamping, tagging, or permanent printing to ensure clear identification during handling, storage, and transportation, as per BIS marking requirements.
Validity for Industrial Welding Cable BIS License
| particulars | Details |
|---|
| Validity | Typically 1 to 2 years, depending on BIS approval conditions |
| Renewal | Must be renewed before expiry by submitting the application along with the prescribed fee and updated documents |
| Surveillane | Includes periodic factory inspections and market sample testing conducted by BIS |
| Compliance | Continuous following to standard and applicable Quality Control Orders (QCOs) is mandatory |
| Risk | Non-compliance or failed sample testing may lead to suspension or cancellation of the BIS license |
Fee Structure for Flexible Welding Cable BIS Approval
The cost of BIS Approval for Welding conductor cable includes charges for application, inspection, license, testing, and marking. These fees are paid to BIS as per Scheme I guidelines.
| Charge Type | Indian Manufacturers | Foreign Manufacturers |
|---|
| Application Fee | INR 1,000 | USD 15 |
| Audit Charges | INR 7,000 | USD 3,200 – 5,900 |
| License Fee | INR 1,000 | USD 15 |
| Marking Fee | As applicable | As applicable |
| Testing Charges | As applicable | As applicable |
| EVTL India Consultancy Fee | As per actual | As per actual |
Note:
- Application fee for foreign manufacturers is payable via SWIFT (SAARC countries may pay in INR with applicable GST).
- Audit charges for foreign manufacturers vary based on country/location.
- The marking fee is determined based on the product category and production volume (MSME benefits may apply).
- Testing charges are paid directly to BIS-recognised laboratories.
- Consultancy fees may vary depending on product type and factory location.
Conclusion
Welding cables play a vital role in ensuring stable and safe welding operations. The working of the cables has a direct effect on the efficiency of workers. The certification of the product ensures that the cables have met all the safety requirements and performance standards. It also helps prevent electrical hazards during operation. The compliance with BIS standards is necessary for ensuring the safety of the welding cables. Certifications indicate that the cables comply with the standards required by the BIS. EVTL India provides guidance in obtaining the certification for manufacturers. It offers help related to documentation, testing, and avoiding unnecessary delays in the certification process.
