Jyoti Electricals, Vadodara, Double Wall Corrugated Pipes And Services

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


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


bricks (9 nos. per

meter) + loading of

brick+transportation 27.00


pipe+loading of


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

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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“


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


- resistance to chemical fluids


- universal application



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“


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


Example of a broken concrete sewer

36


Load!Flexibility!

- Definition of „flexible pipe systems“


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


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


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


Standard: EN 1446 – determination of ring flexibility

“constant speed”



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


Typical example: EN 1446

Test passed Test failed

1.) Visual inspection

45

EN 13476-3: 2007


Standard: EN 744 – determination of impact behaviour



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


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


- resistance to chemical fluids


- universal application


Requirements on a good sewage pipe system:


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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Jyoti Electricals, Vadodara, Double Wall Corrugated Pipes And Services