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DOUBLE WALL CORRUGATEDHDPE PIPES for:
- cable ducts - sewer application- drainage
by
Jyoti ElectricalsGF/10 Ruby Appartment,Opp : Navjivan Bus Stop,Ajwa Road, Vadodara.
3
Double Wall Corrugated Pipe
( DWC PIPE)
outside corrugated
inside smooth
PRODUCT Details
• Name of Product: Double Walled Corrugated pipe from SIZE 50mm OD to 1200mm OD in discrete sizes.
• Relevant specification:• For Cable Ducting :
• IS: 14930(part II): 2001, • BSEN 50086-1 and 50086-2-4.
• For Drainage: • BS EN 13476-1:2007, BS EN 13476-2:2007, BS EN 13476-
3:2007• pr EN 13476-1, 2 and 3
• Application:• Underground cable protection conduit and cable protection ducts for
Electrical and Communication installations
• Sewage & Drainage
5
Comparison
DWP versus solid wall pipe
corrugated pipe
solid wall pipe
6
Comparison DWP versus solid wall pipe
Same stiffness
/smooth pipesmooth pipe
7
Comparison DWP versus solid wall pipe
Same weight
8
ComparisonDWP versus spiral pipe
corrugated pipe
= much higher output
= continuous
production process
= lower weight
spiral pipe
= 6 meter bars only
= only from 400 mm
onwards
9
corrugated pipeGRP, concrete and clay pipes
ComparisonDWP versus rigid pipe systems
Sr.
No.
Properties Precast
concrete
Pipes
(RCC/Spun)
PVC
Pipes
6kg./cm2
pressur
e
Plain
HDPE
pipes
6kg./cm2
pressure
Sait
Glazed
Stoneware
pipes
GI pipes DWC Pipes
1. Flexibility The trenching
path is
seldom
straight, it is
required to
have lateral
curvatures
and ups &
downs, with
RCC pipes
this has to be
tackled with
acute corners
at joints.
Limited
flexibility
but the
pipes at
bends
become
s oval
and
creates
obstructi
on for
cables.
Limited
flexibility
but the
pipes at
bends
becomes
oval and
creates
obstruction
for cables.
For the
pipe to be
laid along
the trench
path, very
high
number of
joints and
fittings are
required to
create
bends.
No
flexibility
at all
With inherently built
moderate flexibility,
these pipes tackle the
trench path by aligning
with it with smooth
Curves (horizontal &
vertical). The
uniqueness of DWC
pipes is that even at
curves the internal
roundness is retained.
In case if plain plastic
pipes ovality is
observed at curvatures.
COMPARISON CHART
Sr.
No.
Properties Precast
concrete
Pipes
(RCC/Spun)
PVC
Pipes
6kg./cm2
pressure
Plain
HDPE
pipes
6kg./cm2
pressure
Sait Glazed
Stoneware
pipes
GI pipes DWC Pipes
2. Soil
settlements
Leads to
cracking of
pipes or
joints, in the
already laid
duct,
because the
pipe is
unable to
align to new
contours.
No
cracking
but same
problem
as
mentioned
in point
(1).
No
cracking
but same
problem as
mentioned
in point (1).
The pipe is
extremely
brittle and
fragile hence
soil
settlement
lead to
cracking of
joints as well
as pipe itself.
Creates
stresses
at joints
and in
the pipe
due to
rigidity.
As characterized
in point (1) soil
settlements do
not adversely
affect the already
laid duct
3. Co-efficient
of friction
Very high.
May lead to
damage to
cable cover
of sub-ducts ,
at time of
insertion.
Low Low Very high Very
high.
May
damage
cable
sheath
Low. Internal
surface of the
pipe being plain
,poses no
difficulty in cable
insertion.
COMPARISON CHART
Sr.
No
.
Properties Precast concrete
Pipes (RCC/Spun)
PVC
Pipes
6kg./cm2
pressur
e
Plain
HDPE
pipes
6kg./cm2
pressure
Sait
Glazed
Stoneware
pipes
GI pipes DWC Pipes
4. Number of
joints
More number of
joints due to pipe
length equal to 3
mtr last concrete
pipes (RCC
/Supn).
Less
6kg./cm2
pressur
e
Less
Plain
HDPE
pipes
6kg./cm2
pressure
Very high
number of
joints salt
glazed
stoneware
Pipes
Joints at
every bend
in the trench
path. GI
pipes
Less number of
joints, because
pipe is available
in 6 mtr. Is
available DWC
pipes.
5. Joining
Method
Cement, sand has
to be available at
site & mixed.
Further, curling
time is required.
Creates,
permanent joint &
hence if
occasional
dismantling is
required, the joint
has to be break
opened.
Easy Very
difficult
requires
welding
Threaded
joints
require
turning/
rotating of
fittings of
pipes.
Cement is
required.
Cumber
some
requiring
number of
tools. Hence
more
suitable for
above
ground
applications
Due to snap-on-
type joints.
Inspite of being
HDPE, no
welding is
required. Fusion
welded joint also
can be used if a
joint with best
possible pulling
strength is
required
COMPARISON CHART
Sr.
No.
Propertie
s
Precast concrete
Pipes (RCC/Spun)
PVC
Pipes
6kg./c
m2
pressur
e
Plain
HDPE
pipes
6kg./cm2
pressure
Sait
Glazed
Stoneware
pipes
GI
pipes
DWC Pipes
6. Transport Transport charges are
high due to loading
and un-loading
difficulties. Further, like
hood of breakage
exists in loading
operations. Material
handling equipment
like chain blokes and
tripod is required at
site.
Easy Easy Transport
damages
are
extremely
high due
to fragility
of pipe
---- There is an absolute
ease in transporting,
loading, unloading
etc. to the extent
that the driver all by
himself can handle
his consignment
without any need for
collies.
7. Labour at
site
An mentioned in point
(6)considerable labour
at the time of laying ,
lowering and jointing
operations.
Less
labour
require
d.
Less but
specially
trained
labour
required
Considera
ble labour
required.
Careful
handling
required.
Skille
d
labou
r
requi
red.
Even a single
person can handle
these operations.
COMPARISON CHART
Sr.
No.
Propertie
s
Precast
concrete Pipes
(RCC/Spun)
PVC
Pipes
6kg./cm2
pressure
Plain HDPE
pipes
6kg./cm2
pressure
Sait Glazed
Stoneware
pipes
GI
pipes
DWC Pipes
8. Speed of
work
As a
consequence of
point (4), (5) &
(6), the speed of
work is slow.
Fast Not as fast
as PVC or
DWC.
As a
consequen
ce of point
(4), (5) (6)
& (7), the
speed of
work is
slow.
---- As a consequence
of point (4), (5) (6) &
(7), the speed of
work is fast.
9. Laying
cost
Due to heavy
weight the cost
of the laid duct
works out to be
very high.
Low Low Cost of laid
duct works
out tobe
very high
High Due to lightweight
the cost of the laid
duct works out to be
very high.
COMPARISON CHART
Sr.
No.
Properties Precast concrete
Pipes
(RCC/Spun)
PVC
Pipes
6kg./cm2
pressure
Plain
HDPE
pipes
6kg./cm2
pressur
e
Sait
Glazed
Stoneware
pipes
GI
pipes
DWC Pipes
10. Chemical
and anti
corrosive
properties
and
biological
properties
Has limited
suitability in
acidic and
alkaline climates.
May support
biological growth.
Moderate Good Chemical
properties
are better
than RCC
pipes.
Very
poor
High degree of
chemical interns &
high anti-corrosive
properties. Facilitates
use in aggressive
climates and soil
conditions, including
saline lands. Does not
support biological
growth.
COMPARISON CHART
COST COMPARISON BETWEEN SUPPLY AND LAYING OF
RCC/ GI AND DWC PIPE
16
Cost Comparison
Cost Comparison of Material and Laying of 100mm dia pipe of various material
Parameter RCC (NP_II) GI Pipe (B Class) DWC HDPE pipe
Comment Cost per meter Comment Cost per meter Comment Cost per meter
Cost of Pipe per meterThis includes cost
of pipe+loading of
pipe+transportation
150
This includes cost of
pipe+loading of
pipe+transportation 575.00
This includes cost
of pipe+loading of
pipe+transportation 150.00
Cost of Trenching Same in all cases Same in all cases Same in all cases
Cost of Unloading pipe at siteAtleast 2 labor and
crane for safe
unloading without
damaging pipe 5.00
Atleast 2 labor
required 3.00
Unloading one
truck having 2500
mtr pipe require
three labor @ Rs
100 per Labor 0.15
Local Cartaige and Laying
Cost
Laying involves 2
persons to lay 2
meter pipe 5.00
Laying involved
atleast two persons
for every 6 meters 3.00
One man required
to lay 6 meter pipe 3.00
Jointing of PipeCement(1kg) and
Sand(4 kg) of ratio
of 1:4 required
along with mason 35.00
Coupler andSkilled
labor required with all
tool kit 80.00
Easy Snapfit
coupler provided
for every 6 meter
@ 30/- per coupler 5.00
Curing at Jointsjoint not available
immediately and
require curing 10.00 No Curing required No curing required
TOTAL 205.00 661.00 158.15
Life of DWC HDPE PIPE IS 50 years
Comparison between DWC and Brick Laying
17
Cost Comparison
Cost Comparison of Material and Laying of cables under BRICK and Half split DWC PIPE
Size of brick 225*112*75 mm (width is 225mm and length is 112mm)
Size of equivalent pipe 77/63mm (77mm is OD and 63mm is ID)
Parameter Brick protection (Class B) Half split DWC pipe
Comment Cost per meter Comment Cost per meter
Cost of Pipe/ brick per meter
This includes cost of
bricks (9 nos. per
meter) + loading of
brick+transportation 27.00
This includes cost of
pipe+loading of
pipe+transportation 40.00
Cost of Trenching Same in all cases Same in all cases
Cost of Unloading pipe/ brick at siteCost per meter 1.00 Only one labor required 0.10
Local Cartaige and Laying Cost Laying involves 2
persons carry 9 bricks 4.00
Laying involved one
persons for every 6
meters 3.00
TOTAL 32.00 43.10
Other advantages of half split DWC pipe over Brick Laying
1. Bricks are not of uniform quality, whereas half split DWC of uniform quality
2. Bricks give protection from above only whereas half split DWC gives protection from 3 sides
3. Whenever there is heavy rain, the bricks ususally are unable to stand water, whereas half split DWC pipe is able to stand
4. DWC is more reliable and has much longer life than bricks as made out of HDPE
5. The bricks usually breaks whenever there is heavy load whereas due to its structure half split DWC pipe is able to take this load
18
The DWC Application
- Definition of „rigid pipe systems“
Explanation of the problematic „cracks“
Load!Crack!
The pipe is stiffer than
the surrounded soil so
it has to take over all the
existing load ...
... until it breaks!
19
The DWC Pipe application
Load!Flexibility!
- Definition of „flexible pipe systems“
Explanation of the problematic „cracks“
The pipe avoids the
load by deflection! The
surrounded soil takes
over all the load.
The stiffness of the soil is
about 10-200 higher than
the stiffness of the pipe.
The soil determinates the
stiffness of the whole system!
20
DOUBLE WALL CORRUGATEDPLASTIC PIPES
for:
-Cable Ducts
Problems in Conventional Cable laying
21
22
Problems in Conventional Cable laying
23
The DWP in Cable Duct application
What does the end user expect of a good Cable Duct system?
- long durability
- weathering resistance
- resistance to abrasion
- effective working methods
- low installation costs
Cost Effective and safe
- ...
- Smooth insertion and protection of cables
REPETATIVE DIGGING OF ROAD AND PATHS ARE AVOIDED
FOR FUTURE LAYING AND MAINTAINANCE OF CABLES BY
PROVIDING DWC PIPE
PROVISION FOR FUTURE CABLE LAYING
24
Manholes for Cable Jointing and Insertion
DWC pie laid in VIZAG
Layout Drawing of DWC PIPES to be laid for IRDP Projects for
future provision of cables
25
Application of DWC pipe in Cable Ducting
26
-For Cable Laying between Pole to Pole for Street Lighting
-PWD, Delhi
-MCD, Delhi
-NDMC, Delhi
-For Cable Laying in Bus Rapid Transit System (BRTS)
-Ahmadabad
-Delhi
-Indore
DWC pipe in Road Crossings
27
Ease of Laying pipe
Indian Railways
TelecommunicationCompanies
ElectricityBoards
PWD’s
DevelopmentAuthorities
Municipal Corporation
AirportAuthority
BRTS PROJECT
S
CityDevelopment
IndustrialDevelopment
End User
29
DOUBLE WALL CORRUGATEDHDPE PIPES for:
- Sewer application
- Drainage
30
The DWC HDPE in sewage application
What does the end user expect of a good sewage system?
- long durability
- weathering resistance
- resistance to chemical fluids
- resistance to abrasion
- universal application
- effective working methods
- low installation costs
inexpensive and safe
- ...
31
The Existing Sewage System
Inspection of a pipe section of a “rigid” sewer system
32
Problems in existing sewage application
Abrasion CorrosionDestruction
Obstacles in the drain off Cracks Un-tight pipe connection
33
The DWP in sewage application
- Definition of „rigid pipe systems“
Explanation of the problematic „cracks“
Load!Crack!
The pipe is stiffer than
the surrounded soil so
it has to take over all the
existing load ...
... until it breaks!
34
The DWP for sewage application
Example of a broken concrete sewer
35
The DWP in sewage application
Example of a broken concrete sewer
36
The DWP in sewage application
Load!Flexibility!
- Definition of „flexible pipe systems“
Explanation of the problematic „cracks“
The pipe avoids the
load by deflection! The
surrounded soil takes
over all the load.
The stiffness of the soil is
about 10-200 higher than
the stiffness of the pipe.
The soil determinates the
stiffness of the hole system!
37
The DWP in sewage application
Deformation
Conclusion:
is
safety!
38
Installation
Destination trench ...
... for the next 50 to 100 years!
39
Standards for corrugated plastic pipes ...
... in sewage
application
EN 13476-3
Plastic pipe systems for non-pressure
underground drainage and sewerage
CEN
......
40
EN 13476-3: 2007
General characteristics for pipes and fittings
Orange-brown (terracotta): well-known from plain pipes (inside & outside)
White: best for inspection (inside)Black: best UV-protection (outside)
Preferred colours
EN 13476-3: 2007
Mechanical characteristics
Stiffness classes: SN (2) – only for pipe sizes > DN 500
SN 4
SN 8
SN 16 – seldom used
Only low level applications – not for corrugated pipes!
Preferred stiffness class for drainage pipes
Preferred stiffness class for sewer pipes
For high loads and less installation depth
(difficult for PE-HD => stiffer materials: PP and PVC)
France ~ almost 100% SN 8;
Italy and Turkey ~ 80% SN 4 – 20% SN 8;
Scandinavia ~ 80-90% SN8 – others: SN4 and SN 16; ...
In Europe:
42
EN 13476-3: 2007
Mechanical characteristics
Standard:
Formula:
ISO 9969 – determination of pipe stiffness
“constant speed”
- 23° C, 2h conditioning time
- at least 24h after production
S = (0,0186 + 0,025 )F
L x y
y
D
0,03
0,1935
[kN/m²]
measured force => Ring Stiffness S
- 2 parallel plates
- defined testing speed (depends on size)
- until 3,0% deflection of inner diameter
43
EN 13476-3: 2007
Mechanical characteristics
Standard: EN 1446 – determination of ring flexibility
“constant speed”
- 23° C, 2h conditioning time
- at least 24h after production
1.) Conform with (during the test):
2.) Conform with (after the test):
- no decrease of force
- no cracking
- no wall delamination or other types of rupture
- no permanent buckling in the structure of the pipe
- 2 parallel plates
- defined testing speed (depends on
size)
Same as ISO 9969, except:
- until 30% deflection of outer diameter
44
EN 13476-3: 2007
Mechanical characteristics
Typical example: EN 1446
Test passed Test failed
1.) Visual inspection
45
EN 13476-3: 2007
Mechanical characteristics
Standard: EN 744 – determination of impact behaviour
- 0° C, 2h conditioning time
- at least 24h after production
Requirement: TIR not more then 10%
- drop height: (1600) 2000 mm
- defined striker
- defined weight (depends on pipe size)
0,5 kg – 3,2 kg
(True Impact Rate)
46
EN 13476-3: 2007
Physical characteristics
for corrugated pipes only relevant:
Oven test: ISO 12091: 1995
- 23°C, 2h conditioning time
- 300 mm long, cut longitudinally into
two equal-sized sections
No delaminations, cracks or bubbles
- PE/PP: 110°C
47
The DWP in sewage application
20 000 40 000 60 000
Stress cycles endured [-]
Abrasion[mm]
0,5
1,0
2,0
2,5
1,5
3,5
4,0
3,0
4,5
PE-HD
Clay
PPPVC
Concrete
Asbestoscement
Abrasion of different materials
(„Darmstädter Methode“)
Test machine
Abrasion on different sewage pipe systems
48
Summary of corrugated double wall pipes
- long durability
- weathering resistance
- resistance to chemical fluids
- resistance to abrasion
- universal application
- effective working methods
Requirements on a good sewage pipe system:
- low installation costs
inexpensive and safe
- low specific weight
- high resistance to UV radiation
- high impact strength
- no defects caused by rodents (animals)
- high flexibility and elasticity
- less connecting parts
- most efficient hydraulic properties
- very high resistance to chemical fluids
- high abrasion resistance
The corrugated PE or PP pipe gives you the most
suitable system!
- ...
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