Jyoti Electricals, Vadodara, Double Wall Corrugated Pipes And Services

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We are one of the leading supplier of Corrugated Ducting for under-ground Cable Protection Management and Sewer Drainage known as HDPE Double Wall Corrugated (DWC) Pipes.

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Jyoti Electricals, Vadodara, Double Wall Corrugated Pipes And Services

  1. 1. DOUBLE WALL CORRUGATED HDPE PIPES for: - cable ducts - sewer application - drainage by Jyoti Electricals GF/10 Ruby Appartment, Opp : Navjivan Bus Stop, Ajwa Road, Vadodara.
  2. 2. Double Wall Corrugated Pipe ( DWC PIPE) outside corrugated inside smooth 3
  3. 3. 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 134763:2007 pr EN 13476-1, 2 and 3 Application: • Underground cable protection conduit and cable protection ducts for Electrical and Communication installations • Sewage & Drainage
  4. 4. Comparison DWP versus solid wall pipe corrugated pipe solid wall pipe 5
  5. 5. Comparison DWP versus solid wall pipe Same stiffness /smooth pipe 6 smooth pipe
  6. 6. Comparison DWP versus solid wall pipe Same weight 7
  7. 7. Comparison DWP versus spiral pipe corrugated pipe = much higher output = continuous production process = lower weight 8 spiral pipe = 6 meter bars only = only from 400 mm onwards
  8. 8. Comparison DWP versus rigid pipe systems corrugated pipe 9 GRP, concrete and clay pipes
  9. 9. COMPARISON CHART Sr. No. Properties Precast concrete Pipes (RCC/Spun) PVC Pipes 6kg./cm 2 pressur e 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. Plain HDPE pipes 6kg./cm2 pressure Sait Glazed Stoneware pipes GI pipes DWC Pipes 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.
  10. 10. COMPARISON CHART Sr. No. Properties 2. Soil settlements 3. Co-efficient of friction PVC Pipes 6kg./cm2 pressure Plain HDPE pipes 6kg./cm2 pressure Sait Glazed Stoneware pipes GI pipes DWC Pipes 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 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. Precast concrete Pipes (RCC/Spun)
  11. 11. COMPARISON CHART Sr. No . Properties Precast concrete Pipes (RCC/Spun) PVC Pipes 6kg./cm 2 pressur e 4. 5. Number of joints Joining Method More number of joints due to pipe length equal to 3 mtr last concrete pipes (RCC /Supn). Less 6kg./cm 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 2 pressur e Plain HDPE pipes 6kg./cm2 pressure Sait Glazed Stoneware pipes GI pipes DWC Pipes 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. 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-ontype 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
  12. 12. COMPARISON CHART Sr. No. Propertie s Precast concrete Pipes (RCC/Spun) PVC Pipes 6kg./c m2 pressur e 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 7. Labour at site An mentioned in point (6)considerable labour at the time of laying , lowering and jointing operations. Less labour require d. Sait Glazed Stoneware pipes GI pipes 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. 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. Plain HDPE pipes 6kg./cm2 pressure DWC Pipes
  13. 13. COMPARISON CHART PVC Pipes 6kg./cm2 pressure Plain HDPE pipes 6kg./cm2 pressure Sait Glazed Stoneware pipes GI pipes 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. 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. Sr. No. Propertie s Precast concrete Pipes (RCC/Spun) 8. Speed of work 9. Laying cost DWC Pipes
  14. 14. COMPARISON CHART Sr. No. Properties Precast concrete Pipes (RCC/Spun) PVC Pipes 6kg./cm2 pressure Plain HDPE pipes 6kg./cm 2 Sait Glazed Stoneware pipes GI pipes Chemical properties are better than RCC pipes. Very poor DWC Pipes pressur e 10. Chemical and anti corrosive properties and biological properties Has limited suitability in acidic and alkaline climates. May support biological growth. Moderate Good 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.
  15. 15. COST COMPARISON BETWEEN SUPPLY AND LAYING OF RCC/ GI AND DWC PIPE Cost Comparison Cost Comparison of Material and Laying of 100mm dia pipe of various material Parameter Cost of Pipe per meter Cost of Trenching RCC (NP_II) GI Pipe (B Class) DWC HDPE pipe Comment Cost per meter Comment Cost per meter Comment Cost per meter This includes cost of pipe+loading of pipe+transportation Same in all cases Jointing of Pipe Curing at Joints TOTAL This includes cost of pipe+loading of pipe+transportation Same in all cases This includes cost of pipe+loading of 575.00 pipe+transportation Same in all cases 150.00 5.00 Atleast 2 labor required 3.00 Unloading one truck having 2500 mtr pipe require three labor @ Rs 100 per Labor 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 Cement(1kg) and Sand(4 kg) of ratio of 1:4 required along with mason Coupler andSkilled labor required with all 35.00 tool kit Easy Snapfit coupler provided for every 6 meter 80.00 @ 30/- per coupler 5.00 Atleast 2 labor and Cost of Unloading pipe at site crane for safe unloading without damaging pipe Local Cartaige and Laying Cost 150 joint not available immediately and require curing 10.00 No Curing required 205.00 0.15 No curing required 661.00 Life of DWC HDPE PIPE IS 50 years 158.15 16
  16. 16. Comparison between DWC and Brick Laying Cost Comparison Cost Comparison of Material and Laying of cables under BRICK and Half split DWC PIPE Size of brick Size of equivalent pipe Parameter Cost of Pipe/ brick per meter Cost of Trenching Cost of Unloading pipe/ brick at site Local Cartaige and Laying Cost 225*112*75 mm 77/63mm (width is 225mm and length is 112mm) (77mm is OD and 63mm is ID) Brick protection (Class B) Comment Cost per meter Comment This includes cost of bricks (9 nos. per meter) + loading of brick+transportation Same in all cases 27.00 This includes cost of pipe+loading of pipe+transportation Same in all cases 40.00 1.00 Only one labor required 0.10 Cost per meter Laying involves 2 persons carry 9 bricks TOTAL 4.00 32.00 Half split DWC pipe Cost per meter Laying involved one persons for every 6 meters 3.00 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 17
  17. 17. The DWC Application Explanation of the problematic „cracks“ - Definition of „rigid pipe systems“ The pipe is stiffer than the surrounded soil so it has to take over all the existing load ... ... until it breaks! Load! Crack! 18
  18. 18. The DWC Pipe application Explanation of the problematic „cracks“ - 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! Flexibility! Load! 19
  19. 19. DOUBLE WALL CORRUGATED PLASTIC PIPES for: -Cable Ducts 20
  20. 20. Problems in Conventional Cable laying 21
  21. 21. Problems in Conventional Cable laying 22
  22. 22. 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 - Smooth insertion and protection of cables - ...  Cost Effective and safe REPETATIVE DIGGING OF ROAD AND PATHS ARE AVOIDED FOR FUTURE LAYING AND MAINTAINANCE OF CABLES BY PROVIDING DWC PIPE 23
  23. 23. PROVISION FOR FUTURE CABLE LAYING DWC pie laid in VIZAG Manholes for Cable Jointing and Insertion 24
  24. 24. Layout Drawing of DWC PIPES to be laid for IRDP Projects for future provision of cables 25
  25. 25. Application of DWC pipe in Cable Ducting -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 26
  26. 26. DWC pipe in Road Crossings Ease of Laying pipe 27
  27. 27. Indian Railways Telecommunication Companies Electricity Boards PWD’s End User Development Authorities Municipal Corporation Airport Authority BRTS PROJECT S City Development Industrial Development
  28. 28. DOUBLE WALL CORRUGATED HDPE PIPES for: - Sewer application - Drainage 29
  29. 29. 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 30
  30. 30. The Existing Sewage System Inspection of a pipe section of a “rigid” sewer system 31
  31. 31. Problems in existing sewage application Abrasion Obstacles in the drain off 32 Destruction Cracks Corrosion Un-tight pipe connection
  32. 32. The DWP in sewage application Explanation of the problematic „cracks“ - Definition of „rigid pipe systems“ The pipe is stiffer than the surrounded soil so it has to take over all the existing load ... ... until it breaks! Load! Crack! 33
  33. 33. The DWP for sewage application Example of a broken concrete sewer 34
  34. 34. The DWP in sewage application Example of a broken concrete sewer 35
  35. 35. The DWP in sewage application Explanation of the problematic „cracks“ - 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! Flexibility! Load! 36
  36. 36. The DWP in sewage application Conclusion: Deformation is safety! 37
  37. 37. Installation Destination trench ... ... for the next 50 to 100 years! 38
  38. 38. Standards for corrugated plastic pipes ... ... ... ... in sewage application CEN EN 13476-3  Plastic pipe systems for non-pressure underground drainage and sewerage 39
  39. 39. EN 13476-3: 2007 General characteristics for pipes and fittings Preferred colours Black: best UV-protection (outside) White: best for inspection (inside) Orange-brown (terracotta): well-known from plain pipes (inside & outside) 40
  40. 40. EN 13476-3: 2007 Mechanical characteristics Stiffness classes: SN (2) – only for pipe sizes > DN 500 Only low level applications – not for corrugated pipes! SN 4 Preferred stiffness class for drainage pipes SN 8 Preferred stiffness class for sewer pipes SN 16 – seldom used For high loads and less installation depth (difficult for PE-HD => stiffer materials: PP and PVC) In Europe: France ~ almost 100% SN 8; Italy and Turkey ~ 80% SN 4 – 20% SN 8; Scandinavia ~ 80-90% SN8 – others: SN4 and SN 16; ...
  41. 41. EN 13476-3: 2007 Mechanical characteristics Standard: ISO 9969 – determination of pipe stiffness “constant speed” - 23° C, 2h conditioning time - at least 24h after production - 2 parallel plates - defined testing speed (depends on size) - until 3,0% deflection of inner diameter  measured force => Ring Stiffness S Formula: S = (0,0186 + 0,025 y D 0,03 42 0,1935 ) F Lxy [kN/m²]
  42. 42. 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 - 2 parallel plates - defined testing speed (depends on size) Same as ISO 9969, except: - until 30% deflection of outer diameter 1.) Conform with (during the test): - no decrease of force - no cracking 2.) Conform with (after the test): 43 - no wall delamination or other types of rupture - no permanent buckling in the structure of the pipe
  43. 43. EN 13476-3: 2007 Mechanical characteristics Typical example: EN 1446 1.) Visual inspection Test passed 44 Test failed
  44. 44. EN 13476-3: 2007 Mechanical characteristics Standard: EN 744 – determination of impact behaviour - 0° C, 2h conditioning time - at least 24h after production - drop height: (1600) 2000 mm - defined striker - defined weight (depends on pipe size) 0,5 kg – 3,2 kg Requirement: TIR not more then 10% (True Impact Rate) 45
  45. 45. 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 - PE/PP: 110°C  No delaminations, cracks or bubbles 46
  46. 46. The DWP in sewage application Abrasion on different sewage pipe systems Abrasion[mm] 4,5 4,0 Asbestos cement 3,5 3,0 Clay 2,5 2,0 1,5 Test machine Concrete 1,0 PVC 0,5 20 000 40 000 60 000 Stress cycles endured [-] Abrasion of different materials („Darmstädter Methode“) 47 PP PE-HD
  47. 47. Summary of corrugated double wall pipes Requirements on a good sewage pipe system: - long durability - low specific weight - weathering resistance - high flexibility and elasticity - resistance to chemical fluids - high impact strength - resistance to abrasion - high abrasion resistance - universal application - less connecting parts - effective working methods - no defects caused by rodents (animals) - low installation costs - high resistance to UV radiation - ... - most efficient hydraulic properties  inexpensive and safe - very high resistance to chemical fluids  The corrugated PE or PP pipe gives you the most suitable system! 48

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