The HDD Coating Revolution: How Engineers Scaled Field Overwraps into a Mainline Factory Process

In this presentation, attendees will discover how Welspun Corp Ltd and Denso engineered a groundbreaking factory-line method to apply composite overwrap protection for horizontal directional drilling (HDD) applications. Moving away from traditional field applications, this session breaks down how a hand-applied material was scaled into a seamless, high-speed plant process on 36-inch, FBE-coated mainline pipe.

Key Takeaways Include:

• The 12-Operator Synchronised Workflow: How controlled mechanical pipe rotation and defined crew roles achieved a steady production pace of 3 meters every 2 minutes.
  
  
• Preserving Coating Integrity: How surface preparation was optimised using solvent cleaning instead of abrasive blasting, avoiding risk to the primary corrosion barrier.
  
  
• Optimised Pipe-End Details: Strategic modifications to factory end terminations to prevent excessive layer buildup during future field girth welding and pullback.
  
  
• Tailored Quality Control Protocols: Adapted inspection methodologies, including multi-point Shore D hardness testing and non-destructive performance checks designed specifically for fiber-reinforced overwraps. 

Gain actionable insights into converting field procedures into repeatable factory operations while ensuring heavy-duty mechanical protection for trenchless pipeline installations.