DOUBLE WALL CORRUGATED (DWC) PIPES

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It is a double layer pipe with the outer layer having corrugation and the inner layer with a smooth surface. The outer corrugated layer substantially increases the stiffness of the pipe, which enables the pipe to take same burial load at a fraction of the weight of Solid wall pipes of the same size.

It is a technically superior and cost effective solution for drainage and sewerage systems over conventional DI & RCC pipes with a steep reduction in installation time and equipment hiring cost. These pipes are available in sizes ranging from 100mm DN/ID to 1200mm DN/ID having ring stiffness ranging from SN2.5 to SN16. Inner layer can be in different colours, with the outer layer in black colour.

There are manufactured as per following standards.

• IS 16098 Part II
• ISO-21138 Part III
• IS-14930
• BS EN 50086

QUALITY TESTS PERFORMED

• Density Test
• Mass Melt Flow Rate Test
• Ring Flexibility
• Ring Stiffness
• Impact Strength
• Water Tightness
• Thermal Stability
• Creep Ratio (Oxidation Induction Test)

DIMENSIONS OF DWC PIPE

Double Wall Corrugated (DWC) HDPE pipes are similar to normal HDPE pipes except that they have different external & internal surfaces which gives them additional strength and stiffness. These are made with High Density Polyethylene which has very high life expectancy. These are externally corrugated and have smooth surface inside and are available from 75 mm to 1.0 m dia. These pipes are light weight and can be used for non-pressure underground sewerage, drainage & cross drainage (pipe culvert) including rain water harvesting purposes. They are maintenance free and therefore, once installed, will lie underground for years.

It is well-known that corrugated pipes can offer exceptional material savings, good hydraulic (flow) properties and high compression strength. For these reasons corrugated pipes have shown high growth rates in recent years resulting in the continued development of its production technology. Here we aim to give you an overview of the main characteristics, types and production technologies of corrugated pipes and show how well the corrugated pipe for sewage and drainage applications acquits itself compared to its two main competitors, the concrete pipe and the solid wall PE pipe.

In the early days corrugated pipes benefitted from the growth in demand for telecommunication cable ducting. But in terms of material conversion tonnage, cable ducting has now been overtaken by drainage and sewage pipes for construction and infrastructure. Corrugated pipes can be made of a wide range of different materials such as polyamide (PA),thermoplastic elastomers (TPE), thermoplastic rubber (TPR), polytetrafluoroethylene (PTFE), but the primary raw material in the manufacture of corrugated pipes for water transportation is high-density polyethylene (HDPE), followed by polypropylene (PP) and polyvinyl chloride (PVC).

Extruded corrugated pipe coming out of corrugator Protos 270 with maintenance-free cooling system with high water discharge, fast mould block change and different vacuum zones with variable positioning (photo: Maincor)

Corrugated pipes can be as small as 1 mm. In the smaller diameter range up to 50 mm they are usually used for cable protection systems in house installations, and the medical, automotive and food industries. Mid-sized corrugated pipes (50 mm ID to 500 mm OD) are commonly used as protection pipes, drainage, sewage, storm water, civil engineering and conveyor pipes. And in the larger sizes up to 3,000 mm, the pipes are employed for storm water, sewage, control shafts, conveyor pipes and manholes.

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Description

INTRODUCTION
THERE ARE MANUFACTURED AS PER FOLLOWING STANDARDS.
QUALITY TESTS PERFORMED
DIMENSIONS OF DWC PIPE
DWC PIPE FOR NEW GENERATION
ADVANTAGES OF DWC PIPES
THERE ARE NUMEROUS OTHER FEATURES OF DWC PIPES & THOSE ARE:
USES OF DWC HDPE PIPES
MERITS OF DWC HDPE PIPES
MERITS OF DWC HDPE PIPES:
B.I.S. SPECIFICATION
ADVANTAGE OF DWC CORRUGATOR MACHINE
DRAINAGE PIPES
ELECTRICAL DUCTS
AGRICULTURE & IRRIGATION WORK
PRODUCTION TECHNOLOGIES OF DWC PIPE
SINGLE WALL PIPE
DUAL/DOUBLE WALL PIPE
QUALITY CONTROL FOR HDPE
CORRUGATED PIPE STANDARDS AND SN / SR COMPARISON
POINTS TO BE TAKEN INTO CONSIDERATION
EXAMINATION AND TESTING OF CORRUGATED PIPES
PIPE AND ARTICULATION COMPONENT TESTS
TECHNICAL PROPERTIES OF PE CORRUGATED PIPES
TABLE: TECHNICAL PROPERTIES OF CORRUGATED PIPES
DOUBLE WALL CORRUGATED PIPES
DIMENSIONS AND WEIGHTS FOR STANDARD DOUBLE WALL
CORRUGATED PIPES, WITH AN INTEGRATED COUPLING SLEEVE
RECENT PROJECTS – CORRUGATED PIPES, FITTINGS, MANHOLES,
INSPECTION CHAMBERS, DRAINAGE PIPES
COMPARISON OF CORRUGATED PIPE WITH OTHER CONVENTIONAL PIPES
CORRUGATED PIPE VERSUS SOLID WALL PIPE
CORRUGATED VERSUS SPIRAL PIPE
TECHNICAL DETAILS OF CORRUGATED PIPE
TYPICAL PRODUCT SPECIFICATION:
DIAMETER AND CLASSES
NOMINAL PRESSURE CLASSES IS 1 BAR
DOUBLE CORRUGATED PIPE WALL STRUCTURE
PIPES ENDS
HYDRAULIC SEALING
FITTINGS
MANUFACTURING PROCESS DESCRIPTION:
TESTING
PROCESS EQUIPMENT
TECHNICAL DATA:
II. DIE HEAD
III. FORMING MACHINE
IV. SPRAY BATH
V. CUT-OFF UNIT
VI. STACKER
THE COMPOSING OF PRODUCTION LINE:
E: MECHANICAL PARTS
II. EXTRUSION DIE HEAD
III. SBZ1000 FORMING MACHINE
MODEL OF FORMING MACHINE: SBZ1000 (HORIZONTAL TYPE MACHINE)
IV. SPRAY BATH
V. CUT-OFF UNIT
VI. STACKER
MARKET OVERVIEW OF HDPE PIPES
PRODUCTION OF HDPE IN INDIA
CONSUMPTION OF HDPE IN INDIA
IMPORT OF HDPE
OVERVIEW OF CONSTRUCTION INDUSTRY IN INDIA
THE NATIONAL INFRASTRUCTURE PIPELINE (NIP)
GOVERNMENT INITIATIVES
CONCLUSION
PRESENT MANUFACTURERS/SUPPLIERS OF DWC HDPE PIPES
HDPE/PP/PVC DOUBLE WALL CORRUGATED PIPE PRODUCTION LINE
MANUFACTURING PROCESS
PHASE I
PREPARATION OF RAW MATERIAL (RM)
APPROVAL OF RM FOR PURCHASE ORDER
RECEIVING / STORAGE
IF THE LOT IS COMPLIANT, IT IS STORED AND REGISTERED.
MIXTURE
PHASE II
EXTRUSION
PHASE III
CORRUGATION
THIS RECENT TECHNOLOGY IS UNDER STUDY.
PHASE IV
CALIBRATION
PHASE V
FINISHING AND PACKAGING
CONTROLS AND TESTS
TECHNICAL REQUIREMENT OF DOUBLE WALLED CORRUGATED
(DWC) HDPE DUCT
SCOPE:
REQUIREMENTS:
GENERAL INFRASTRUCTUR:
QUALITY CONTROL:
ESSENTIAL MACHINERY & PLANT REQUIRED FOR PRODUCTION:
REQUIRED ESSENTIAL MACHINERY & PLANT SHALL BE AS FOLLOWS
ESSENTIAL TESTING EQUIPMENTS REQUIRED FOR QUALITY ASSURANCE
REQUIRED ESSENTIAL TESTING EQUIPMENTS SHALL BE AS FOLLOWS
QUALITY ASSURANCE FLOW CHART FOR DWC HDPE DUCT
JOINING SYSTEM AND INSTALLATION OF DWC PIPES
JOINTING PROCEDURE
CONSTRUCTION OF BACKFILL ENVELOPE AND BACKFILLING
OF THE TRENCHES
TRANSPORTATION, HANDLING AND STORAGE OF DWC PIPES
TRANSPORTATION OF DOUBLE-WALL PIPE TO THE WORKSHOP
STORAGE AND MAINTENANCE OF DOUBLE-WALL CORRUGATED PIPE
INSTALLING DOUBLE-WALL CORRUGATED PIPES
DETAILS OF CORRUGATOR LINE
LAYOUT OF A PRODUCTION LINE:
DOWNSTREAM EQUIPMENT
PRODUCTION TECHNOLOGIES
» UNICOR‘S CLOSED CONSTRUCTION TECHNOLOGY
FEATURES:
» UNICOR‘S SHUTTLE CORRUGATORS
FEATURES:
» UNICOR‘S OPEN HORIZONTAL CHAIN CORRUGATORS
FEATURES:
PRODUCTION TECHNOLOGIES
» DIE HEADS:
› SWESY DIE HEAD FOR SMALL-/MID-SIZED DOUBLE WALL PIPES
SWESY DIE HEAD – ADVANTAGES
› DISC DIE HEAD FOR MID-/LARGE-SIZED DOUBLE WALL PIPES
DISC DIE HEAD – ADVANTAGES
» UNICOR COOLING MANDREL TECHNOLOGY GUARANTEES:
PRODUCTION TECHNOLOGIES
» MOULD BLOCKS
CONNECTION TECHNIQUES
TESTNG METHOD OF DWC PIPES
CREEP RUPTURE STRENGTH – INTERNAL PRESSURE TEST
CONSTANT INTERNAL PRESSURE AT CONSTANT TEMPERATURE
STRESS CRACK RESISTANCE – PIPE NOTCH TEST
SLOW CRACK GROWTH TESTING
RESISTANCE TO RAPID CRACK PROPAGATION – S4 TEST
RCP PHENOMENON SIMULATION IN PLASTIC PIPES
CREEP RUPTURE STRENGTH – INTERNAL PRESSURE TEST
RESISTANCE TO INTERNAL PRESSURE
RECOMMENDED TESTING PROCEDURE FOR HDPE PIPES
PRESSURE TESTING OUTSIDE THE TRENCH:
TESTING IN THE TRENCH:
COMPLETE DOUBLE WALL CORRUGATED HDPE PIPE MAKING PLANT
& EQUIPMENTS SUPPLIERS
SUPPLIERS OF PLANT AND MACHINERY (IMPORTED)
COMPLETE DOUBLE WALL CORRUGATED HDPE PIPE MAKING PLANT
& EQUIPMENTS SUPPLIERS
SUPPLIERS OF AIR POLLUTION CONTROL EQUIPMENTS
SUPPLIERS OF EOT CRANES
SUPPLIERS OF DG SETS
SUPPLIERS OF POWER TRANSFORMERS
SUPPLIERS OF COOLING TOWER
SUPPLIERS OF ETP PLANTS
SUPPLIERS OF MEASURING AND TESTING INSTRUMENTS
SUPPLIERS OF RAW MATERIALS
SUPPLIERS OF HDPE RESIN
SUPPLIERS OF HDPE GRANULES

APPENDIX – A:

01. PLANT ECONOMICS
02. LAND & BUILDING
03. PLANT AND MACHINERY
04. OTHER FIXED ASSESTS
05. FIXED CAPITAL
06. RAW MATERIAL
07. SALARY AND WAGES
08. UTILITIES AND OVERHEADS
09. TOTAL WORKING CAPITAL
10. TOTAL CAPITAL INVESTMENT
11. COST OF PRODUCTION
12. TURN OVER/ANNUM
13. BREAK EVEN POINT
14. RESOURCES FOR FINANCE
15. INSTALMENT PAYABLE IN 5 YEARS
16. DEPRECIATION CHART FOR 5 YEARS
17. PROFIT ANALYSIS FOR 5 YEARS
18. PROJECTED BALANCE SHEET FOR (5 YEARS)

Additional information

Plant Capacity

20 MT/Day
Land & Building

(8000 sq.mt.)
Plant & Machinery

US$ 881428
Rate of Return

34%
Break Even Point

49%

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