In the heavy industrial sector, safety and durability are paramount. Welding operations, particularly in shipyards, automotive manufacturing, and construction, require cables that can withstand extreme conditions. This is where IS 9857:1990 comes into play.
If you are a manufacturer or importer of welding cables, understanding the Bureau of Indian Standards (BIS) requirements is not just about quality assurance—it is a legal necessity. Under the Cables (Quality Control) Order, 2020, welding cables generally fall under the mandatory certification list, meaning they cannot be sold, manufactured, or imported in India without a valid ISI Mark.
What is IS 9857:1990?
IS 9857:1990 is the Indian Standard specification that covers Insulated & Sheathed Welding Cables. These are single-core, flexible cables designed specifically to transmit high currents from the electric welding machine to the welding tool (electrode holder).
Unlike standard house wiring, welding cables must endure rough handling, dragging across abrasive surfaces, exposure to oil and grease, and significant thermal shocks. Therefore, IS 9857 specifies that these cables must use HOFR (Heat Resisting, Oil Resisting, and Flame Retardant) elastomeric insulation to ensure safety and longevity.
Why is BIS Certification Mandatory for Welding Cables?
The Government of India, through the Department for Promotion of Industry and Internal Trade (DPIIT), has issued Quality Control Orders (QCOs) for various electrical products to curb the influx of sub-standard goods.
For welding cables, the mandatory ISI Mark ensures:
- Safety: Protection against electrical shocks and fire hazards in volatile industrial environments.
- Quality: Assurance that the copper or aluminum conductors meet conductivity standards.
- Marketability: Products without the ISI Mark are liable to be seized, and manufacturers can face heavy penalties.
Technical Requirements Under IS 9857
To obtain the license, your product must pass specific laboratory tests defined by BIS. Key parameters include:
- Conductor Material: The standard allows for high-conductivity annealed copper or aluminum. Flexibility is a critical test parameter.
- Insulation Material: The covering must be durable. The standard mandates tests for tensile strength and elongation at break of the insulation.
- HOFR Test: The cable is subjected to oil immersion and heat treatment to verify it does not degrade, swell, or lose its flame-retardant properties.
- High Voltage Test: Ensuring the cable can handle the designated voltage without breakdown.
- Resistance Test: Verifying that the conductor resistance falls within the permissible limits to prevent overheating.
BIS Certification Process for Welding Cables
Obtaining the ISI Mark involves a systematic process under Scheme-I of the BIS conformity assessment.
Step 1: Documentation & Application The manufacturer must prepare technical documents, including the factory layout, list of machinery, quality control personnel details, and manufacturing flowcharts. An application is then submitted on the Manak Online portal.
Step 2: Factory Inspection A BIS officer will visit the manufacturing unit to audit the production process and the in-house testing facilities. They will verify that you have the necessary testing equipment (like tensile testing machines and ohmmeters) to maintain daily quality standards.
Step 3: Sample Drawing & Testing During the audit, the officer will draw random samples of the welding cables. These are sealed and sent to a BIS-recognized third-party laboratory for independent testing against IS 9857 parameters.
Step 4: Grant of License If the factory audit is successful and the independent lab report confirms the product meets the standard, the BIS license is granted.
Documents Required for BIS Registration
To fast-track your application with Instacertify, ensure you have the following ready:
- Proof of office and factory address (e.g., Business License, Rent Agreement).
- MSME/SSI Registration certificate (if applicable).
- List of Manufacturing Machinery.
- List of Testing Equipment with valid calibration certificates.
- Process Flow Chart.
- Details of the Quality Control Manager (Degree/Diploma certificate).
- Trademark Registration copy.
Frequently Asked Questions (FAQ)
Q1. Is the ISI Mark mandatory for imported welding cables?
Yes. Under the Foreign Manufacturers Certification Scheme (FMCS), foreign manufacturers must obtain a BIS license and print the ISI Mark on their cables before exporting them to India.
Q2. What is the validity of the BIS license for IS 9857?
The license is initially valid for two years and can be renewed subsequently.
Q3. Can I manufacture welding cables with PVC insulation under IS 9857?
No, IS 9857 specifically covers elastomeric (rubber-like) insulation. PVC insulated cables are covered under different standards.
