16 sq mm welding cable — right size, right life, right value

Specifying a 16 sq mm welding cable means you’re after a conductor that carries meaningful current while remaining flexible and manageable on the job. That balance — current capacity, flexibility, and durability — determines whether a lead performs for months or becomes a recurring expense. This guide explains what to look for on a product page, how to size and terminate leads correctly, and why the cheapest per-metre option is rarely the best long-term choice.

Who buys 16 sq mm welding cable and why

Maintenance teams, small fabricators and installers often pick a 16 sq mm welding cable for portable welding leads, battery interconnects and generator hookup applications. The size provides a sensible compromise: it carries higher currents than small gauges while still remaining light enough to reel and handle without awkward bulk. When teams choose the right construction and jacket, a 16 sq mm welding cable becomes a dependable workhorse that reduces setup time and avoids mid-job failures.

What “16 sq mm” tells you — and what it doesn’t

The cross-section alone doesn’t guarantee performance. Saying “16 sq mm welding cable” only tells you the conductor area; it does not say:

• how the copper is stranded (fine filaments vs coarse strands),

• what jacket chemistry protects the conductor, or

• the cable’s DC resistance at 20 °C (used for voltage-drop math).

Always move from the nominal size to the datasheet. Compare strand count, DCR, outer diameter and jacket specification before you commit to a purchase.

Conductor construction — the most practical spec

The way copper is stranded has a direct impact on flex life, termination quality and electrical behaviour. A 16 sq mm welding cable built from many thin filaments behaves like a rope: it flexes without internal fractures and crimps cleanly into compression lugs. By contrast, coarse-stranded conductors are cheaper but more likely to break near bends and to cause stray wires at terminations. For any frequently handled lead, demand the strand breakdown — it’s the best predictor of real-world longevity.

Jacket chemistry — pick the protective layer to match the environment

The jacket is the mechanical shield that decides whether the cable survives oil, abrasion, cold or sunlight. For heavy-use welding leads choose EPDM or neoprene rubber jackets; they stay supple in low temperatures, resist oils and ozone, and handle abrasion better than PVC. For indoor, low-abuse tasks a PVC jacket can be acceptable, but expect shorter life in harsher conditions. Specify jacket type on purchase orders so what arrives on site fits the duty.

Voltage drop and ampacity — do the calculation

A 16 sq mm welding cable reduces voltage drop compared with smaller sizes, but run length and current still matter. Use the supplier’s DC resistance value to compute end-voltage at your expected welding or continuous current. For welding, where currents spike, check both peak and average values and consult duty-cycle ampacity tables. If the end-voltage falls below equipment tolerance, step up size or shorten the run; don’t rely on guesswork.

Terminations — make the joint part of the spec

Most cable problems show up at terminations, so treat the lug as part of the product. When making a 16 sq mm welding cable assembly:

• choose compression lugs designed for the conductor geometry and stud size,

• crimp with the die the lug manufacturer specifies and verify the mechanical crimp,

• use strain-relief boots and heat-shrink to avoid bending stress at the lug, and

• commission critical joints with a thermal check under expected load.

A well-made termination preserves low resistance and prevents hot spots that can damage equipment or cause hazards.

Handling and reel practices — small habits, big payoff

How crews handle reels determines cable life. For every 16 sq mm welding cable in the fleet:

• use reels with a drum diameter that respects the minimum bend radius,

• protect pass-throughs with grommets to avoid chafing on edges,

• clean jackets before rewinding to prevent grit embedding, and

• rotate usage to distribute wear across lengths.

These simple operational habits dramatically increase mean time between failures and reduce replacement costs.

Typical uses — where 16 sq mm performs best

You’ll commonly see a 16 sq mm welding cable used for:

• portable welding leads for site repairs and light fabrication,

• battery interconnects and inverter feeds in vehicles and backup systems,

• generator hookup leads for temporary distribution, and

• flexible feeders for compressors and portable motors.

For each application, match jacket chemistry and strand geometry to the expected mechanical and environmental stresses.

Comparing suppliers — what to demand in your RFQ

To get comparable quotes, include these mandatory fields when you request 16 sq mm welding cable:

1. conductor construction (strand count and filament diameter),

2. DC resistance at 20 °C and rated voltage,

3. jacket/insulation chemistry and operating temperature range,

4. minimum bend radius, outer diameter and packaging (cut tolerances), and

5. required test certificates (mill test, dielectric/hipot) and sample policy.

A tight RFQ forces suppliers to give apples-to-apples offers and reduces the chance of a wrong shipment.

Price vs total cost of ownership — look past the sticker

Per-metre price for a 16 sq mm welding cable varies by strand construction and jacket. Short cut lengths and pre-terminated kits carry a convenience premium; buying reels lowers unit cost. But the cheapest per-metre cable may be the most expensive in practice if coarse strands and weak jackets drive frequent replacements. Include termination labour, downtime and expected replacement rate when you calculate installed cost.

Premium options — when to pay more

There are cases where paying extra is the right choice. Consider these upgrades for demanding duties:

• tinned conductors for marine or corrosive environments,

• ultra-flex constructions with very high strand counts for extreme flex cycles, and

• double-insulated or flame-retardant jackets for hazardous locations.

A modest premium on a 16 sq mm welding cable with those features can reduce downtime and replacement expense in harsh or critical operations.

Quick on-site checks before use

Teach crews to perform a fast pre-use check:

• inspect the jacket along the length for cracks, cuts or flattening,

• verify terminations are clean and strain relief is in place, and

• look for visible signs of overheating or discoloration near lugs.

Stopping to check saves time and prevents most field failures.

Maintenance routine — a few minutes that save hours

Adopt a short maintenance routine:

• log reel IDs and batch numbers for traceability,

• clean and visually inspect cables after heavy use,

• perform thermal imaging on critical terminations during commissioning, and

• replace any cable with exposed strands immediately.

A consistent routine keeps fleets working and minimizes emergency replacements.

Final recommendation — specify precisely, install properly, inspect routinely

When you buy a 16 sq mm welding cable, treat it as part of a system: specify strand geometry for flex life, choose jacket chemistry for the environment, require datasheet numbers for DC resistance and temperature, and insist on correct termination practice. Do that and your leads will be dependable tools that reduce downtime, protect equipment and save money over the long term.