HOFR / TRS Welding Cable IS 9857 | Copper & Aluminium Flexible Welding Cable | Excellent Enterprises
The Excellent Enterprises HOFR / TRS Welding Cable IS 9857 range is engineered for dependable power transmission in professional welding environments where flexibility, durability, and electrical efficiency are critical. Manufactured in compliance with IS 9857:1990 standards (CM/L 2584163), these single-core flexible welding cables are available in both copper and aluminium conductor variants, with HOFR (Heat, Oil & Flame Retardant) and TRS (Tough Rubber Sheathed) insulation options. Designed for fabrication workshops, heavy engineering plants, shipyards, power projects, railway manufacturing, defence production, and industrial welding applications, these cables deliver reliable current flow for demanding arc welding operations.
Why Welding Cable Quality Matters
A welding cable is not just a conductor—it directly influences arc stability, voltage drop, equipment efficiency, and operational safety.
Poor cable quality may lead to:
- Excessive heat buildup
- Higher resistance losses
- Weak arc performance
- Reduced welding efficiency
- Premature insulation failure
- Restricted operator movement
Professionally engineered flexible welding cables ensure smoother current transfer from welding machine to electrode holder or work return path.
The choice between copper and aluminium conductor impacts conductivity, cable weight, and installation practicality, while insulation type determines environmental durability and temperature tolerance.
For professional welding operations, proper cable selection improves performance, uptime, and equipment protection.
Cable Selection Guide
Selecting the correct welding cable depends on welding current, cable run length, electrode size, and application environment.
HOFR Cable Selection
Best for demanding industrial environments where resistance to heat, oil exposure, and flame hazards is important. Suitable conductor temperature up to 90°C.
TRS Cable Selection
Ideal for general-purpose welding operations where robust flexible rubber insulation is required. Suitable conductor temperature up to 60°C.
Copper Conductor Option
Preferred where maximum conductivity, lower voltage drop, and higher welding efficiency are priorities.
Aluminium Conductor Option
Suitable where lighter cable weight and commercial cost efficiency are operational considerations.
Long Cable Runs
For longer cable lengths, larger conductor cross-sections help minimize voltage loss and maintain welding output stability.
Technical Specifications
HOFR / TRS Welding Cable Data (IS 9857)
| Size (Sq mm) | Nominal Thickness of Covering (mm) | Diameter of Cable (mm) | Max Conductor Resistance at 200°C Copper (Ohm/Km) | Approx Wt 100 Mtrs Coils Copper (Kgs) | Max Conductor Resistance at 200°C Aluminium (Ohm/Km) | Approx Wt 100 Mtrs Coils Aluminium (Kgs) |
|---|---|---|---|---|---|---|
| 16 | 2.00 | 10.0 | 1.210 | 23 | — | — |
| 25 | 2.00 | 11.0 | 0.780 | 33 | 1.250 | 17 |
| 35 | 2.00 | 12.5 | 0.554 | 42 | 0.901 | 20 |
| 50 | 2.20 | 15.0 | 0.386 | 58 | 0.654 | 26 |
| 70 | 2.40 | 17.5 | 0.272 | 82 | 0.445 | 39 |
| 95 | 2.60 | 20.5 | 0.206 | 110 | 0.334 | 50 |
| 120 | 2.80 | 22.0 | — | — | 0.256 | 61 |
Recommended Cable Size for Welding Electrodes
| Electrode Size SWG | Electrode Size mm | Equivalent Cable As per IS 434 | HOFR Copper (Sq mm) | HOFR Aluminium (Sq mm) | TRS Copper (Sq mm) | TRS Aluminium (Sq mm) |
|---|---|---|---|---|---|---|
| 14 | 2.00 | — | 16 | 25 | 16 | 25 |
| 12 | 2.50 | — | 16 | 25 | 16 | 25 |
| 10 | 3.25 | 150A | 16 | 25 | 25 | 35 |
| 8 | 4.00 | 230A | 25 | 35 | 35 | 50 |
| 8* | 4.00 | 400A* | 35 | 50 | 50 | 70 |
| 6 | 5.00 | 600A | 50 | 70 | 70 | 95 |
| 4 | 6.00 | 800A | 70 | 95 | 95 | 120 |
| 2 | 7.00 | 1000A | 95 | 120 | — | — |
*Recommended for cable lengths exceeding 15 metres.
Compatible Products
Compatible with:
- MMA / SMAW Welding Machines
- MIG Welding Systems
- TIG Welding Equipment
- Welding Electrode Holders
- Earth Clamps
- Arc Welding Power Sources
- Industrial Inverter Welding Machines
- Heavy-Duty Welding Installations
Applications
These flexible welding cables are designed for demanding electrical current transmission across industrial welding environments.
Recommended applications include:
MMA / SMAW Arc Welding
MIG Welding Operations
TIG Welding Applications
Heavy Structural Fabrication
Shipyard Welding Work
Pipeline Welding Projects
Power Plant Maintenance
Railway Manufacturing Operations
Defence Engineering Applications
An essential electrical component wherever professional welding current delivery is required.
Why Excellent Enterprises
Excellent Enterprises manufactures industrial welding accessories and electrical consumables engineered for practical performance and long operational reliability.
Why professionals choose Excellent Enterprises:
- IS-certified manufacturing quality
- Industrial-grade conductor engineering
- Flexible application compatibility
- Durable insulation construction
- Reliable electrical performance
- Workshop and project-ready supply capability
- Trusted welding equipment expertise
For welding systems, dependable current transmission directly impacts productivity and weld quality.
FAQ
What is HOFR welding cable used for?
HOFR welding cable is used for welding applications requiring flexible current transmission with enhanced resistance to heat, oil, and flame exposure.
What is the difference between HOFR and TRS welding cable?
HOFR offers higher temperature tolerance and greater environmental resistance, while TRS is suited for general-purpose welding cable applications.
Which is better—copper or aluminium welding cable?
Copper offers higher conductivity and lower resistance, while aluminium provides lighter weight and improved commercial cost efficiency depending on application requirements.
How do I choose the correct welding cable size?
Cable size depends on welding current, electrode diameter, cable run length, and operational load requirements.
Is this suitable for industrial welding machines?
Yes. These cables are compatible with MMA, MIG, TIG, inverter, and heavy-duty industrial welding systems.
Are these cables flexible for workshop use?
Yes. These single-core flexible cables are designed for operator movement, equipment connectivity, and practical industrial handling.
