CASE STUDY
Welspun Plant Applied ARO Outerwrap – HDD Pipeline Protection
Denso’s Bore-Wrap – ARO Outerwrap for Pipeline Coating Protection
Project Data
| Location | Anjar, Gujarat, India |
| Completion | 2026 |
| Project Type | Plant-applied HDD full encapsulation |
| Products Used | Denso Bore-Wrap® System |
| Contractor | Welspun Corp. Ltd. |
At Welspun Corp Ltd’s coating facility in Anjar, Gujarat, India, a major HDD pipeline protection project required a new approach to protecting large-diameter, FBE-coated mainline pipe. Each pipe length measured approximately 914 mm (36 in.) in diameter and 18.3 m (60 ft) long, with a completed dual-layer fusion-bonded epoxy (2LFBE) corrosion barrier that needed to remain intact through handling, transportation, field welding, and final horizontal directional drilling pullback. To provide additional mechanical protection without damaging the primary coating, the project team selected Denso Bore-Wrap® as a sacrificial composite outerwrap system for full-length HDD protection.
The defining achievement of the project was the development of a repeatable plant-line application method for Denso Bore-Wrap. Using controlled pipe rotation, managed hydration, 50% spiral overlap, compression wrapping, venting, and cure control, Welspun converted a traditionally hand-applied HDD protection system into a coordinated factory application process for large-diameter pipe. The project demonstrated how plant-applied composite overwrap systems can help protect FBE-coated pipe from shear, abrasion, impact, and gouge forces during demanding trenchless pipeline installations. Download the case study for a full project overview.
PROJECT HIGHLIGHTS
- Plant-Applied HDD Protection: Denso Bore-Wrap® was applied full-length over 914 mm (36 in.) FBE-coated pipe to provide added mechanical protection for demanding HDD installation conditions.
- Repeatable Factory-Line Process: Controlled pipe rotation, hydration, 50% spiral overlap, compression wrapping, venting, and cure control helped convert a hand-applied system into a coordinated plant application method.
- Primary Coating Preserved: The application approach helped protect the completed 2LFBE corrosion barrier while adding a sacrificial composite outerwrap designed to resist shear, abrasion, impact, and gouge forces.
Denso Bore-Wrap® is applied in a controlled plant-line process to provide full-length mechanical protection for large-diameter HDD pipe.
Full-length HDD pipe prepared for factory-line mechanical protection.
Denso Bore-Wrap application begins under controlled plant conditions.
Welspun’s coordinated application team converts a hand-applied system into a repeatable plant process.
Denso Bore-Wrap® is applied in a controlled plant-line process to provide full-length mechanical protection for large-diameter HDD pipe.
Full-length HDD pipe prepared for factory-line mechanical protection.
Denso Bore-Wrap application begins under controlled plant conditions.
