Industry Overview
Double Wall Corrugated (DWC) HDPE pipes are technically advanced, lightweight piping systems consisting of a smooth inner layer and a corrugated outer layer. The corrugated outer wall substantially increases pipe stiffness, allowing the pipe to withstand burial loads with significantly lower weight than solid-wall pipes of the same size. This makes DWC pipes a technically superior and cost-effective solution for drainage and sewerage applications compared with conventional DI and RCC pipes, while also reducing installation time and equipment hiring costs.
DWC HDPE pipes are available in sizes ranging from 100mm DN/ID to 1200mm DN/ID, with ring stiffness classes ranging from SN2.5 to SN16. The inner layer can be manufactured in different colours, while the outer layer is generally black. Manufacturing and product requirements referenced in the report include IS 16098 Part II, ISO-21138 Part III, IS-14930, and BS EN 50086. Quality assurance includes density, mass melt flow rate, ring flexibility, ring stiffness, impact strength, water tightness, thermal stability, and creep ratio testing. The report also covers manufacturing technologies, process equipment, technical specifications, quality control, installation practices, market aspects, and suppliers.
Cost Estimation
| Particulars | Value |
|---|---|
| Plant Capacity | 20 MT/Day |
| Land & Building (8000 sq.mt.) | Rs. 6.64 Cr |
| Plant & Machinery | Rs. 4.62 Cr |
| Working Capital for 1 Month | Rs. 5.34 Cr |
| Total Capital Investment | Rs. 16.91 Cr |
| Rate of Return | 29% |
| Break Even Point | 52% |
Content Index
- 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
- 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
- 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:
- 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
- E: MECHANICAL PARTS
- MATERIAL OF BARREL & SCREW 38CRMOLAA WITH NITROGEN TREATMENT
- II. EXTRUSION DIE HEAD
- III. SBZ1000 FORMING 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
- PRESENT MANUFACTURERS/SUPPLIERS OF DWC HDPE PIPES
- HDPE/PP/PVC DOUBLE WALL CORRUGATED PIPE PRODUCTION LINE
- MANUFACTURING PROCESS
- 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
- SUPPLIERS OF PLANT AND MACHINERY
- SUPPLIERS OF PLANT AND MACHINERY (IMPORTED)
- COMPLETE PLANT SUPPLIERS [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
- 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)
Frequently Asked Questions
A Double Wall Corrugated (DWC) HDPE pipe has a smooth inner wall and a corrugated outer wall. The two-layer construction combines hydraulic smoothness on the inside with enhanced structural stiffness on the outside. The corrugated profile allows the pipe to resist external burial loads efficiently while keeping its weight lower than a comparable solid-wall pipe. DWC HDPE pipes are commonly considered for drainage, sewerage, ducting, and related underground infrastructure applications where strength, handling efficiency, and installation performance are important.
The main advantages of DWC HDPE pipes include high structural stiffness with relatively low weight, a smooth internal surface, easier handling, and efficient installation. Their corrugated outer wall improves resistance to external loads, while the smooth bore supports effective fluid flow. Compared with some conventional drainage and sewerage pipe systems, their lower weight can also help reduce handling and equipment requirements. Performance ultimately depends on pipe design, installation conditions, bedding, backfilling, jointing, and compliance with the applicable product standards.
Quality testing of DWC HDPE pipes includes material, mechanical, dimensional, and performance checks. The report identifies density testing, mass melt flow rate testing, ring flexibility, ring stiffness, impact strength, water tightness, thermal stability, and creep ratio or oxidation induction testing. These tests help verify that the raw material and finished pipe meet specified performance requirements. The selection of tests and acceptance criteria depends on the applicable standard, product specification, pipe application, and quality assurance procedure used by the manufacturer.
The report references IS 16098 Part II, ISO-21138 Part III, IS-14930, and BS EN 50086 for DWC pipe manufacturing and related requirements. Applicable standards establish requirements relating to product construction, dimensions, performance, testing, and other characteristics. Manufacturers should identify the specific standard applicable to their intended product and market and ensure that raw materials, manufacturing processes, testing facilities, and quality documentation are aligned with the relevant requirements.
DWC HDPE pipes are manufactured through a controlled extrusion and forming process that creates separate inner and outer wall structures. The process generally includes preparation and approval of raw material, receiving and storage, material mixing, extrusion, corrugation, calibration, finishing, and packaging. Equipment such as extrusion die heads, forming machines, spray baths, cut-off units, and stackers forms part of the production system described in the report. Process controls and testing are used throughout production to maintain dimensional consistency and required product performance.
DWC HDPE pipes are commonly used for underground drainage, sewerage, ducting, and related infrastructure applications. Their smooth internal wall can support efficient flow, while the corrugated external wall provides structural stiffness for buried installations. The report also covers applications involving fittings, manholes, inspection chambers, and drainage systems. Selection should consider pipe diameter, stiffness class, soil and traffic loading, groundwater conditions, installation depth, jointing method, and applicable project specifications.
Proper trench preparation, bedding, jointing, backfilling, handling, storage, and installation practices are essential for DWC pipe performance. The installation method should account for the pipe's stiffness class, surrounding soil, trench geometry, anticipated loads, and groundwater conditions. Backfill material and compaction should be controlled to provide appropriate support around the pipe without damaging the pipe wall or joints. Transportation and storage should also prevent deformation or mechanical damage before installation, while jointing should follow the specified joining system and manufacturer requirements.
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