Modern metallurgical industry consists of many of supporting and main plants, which require constant material investments. The issue of saving material resources, raw materials, etc., as well as reducing the expenditure coefficient of the metal, optimization and flexibility of production, is an important part for metallurgical companies in the conditions of economic instability in the industrial sector. This article describes the newly developed methods for the production of expandable electric welded pipes from two sheets (double-seam). An assessment of the feasibility of implementing the developed methods was made for the production of large diameter double-seam pipes, using modern engineering analysis methods, based on the finite element method (FEM). Technological modes of shaping were selected to produce products that meet customer requirements. The article describes the results of the experimental work, assesses the convergence of the results obtained using CAE-systems and the experimental work in the plant. The developed mathematical models for the production of pipe billets in the main shaping operations have high convergence and can be used in the calculation of new sizes. The use of the developed mathematical models in the specialized software package MSC Software allows evaluating new technological modes and various production methods without risks and financial losses. The proposed new methods for the production of large-diameter double-seam pipes (forming a sheet from two halves and forming a half cylinder) increased productivity and flexibility of production, and also had a positive economic efficiency, due to lower costs for sheet billet. New production methods have proved their working ability and have proved the possibility of practical application (production of an experimental batch).