Pipe Benders Overview

Pipe bending is an essential part of construction and piping systems. Bridge, stairs, and canopy construction uses curved pipes, and bending pipes in a piping system reduces the number of connections. Pipe benders can be manual, electric, or hydraulic, and each type has pros and cons. Also, different methods are used when bending pipe, depending on the bend requirement and pipe material. This article describes the types of pipe benders, pipe bending methods, and applications for pipe bending. For an example on how to bend a pipe, read our article on how to bend a copper pipe.

Table of contents

• Pipe bending tools
• Pipe bender pros & cons
• Pipe bending methods
• Pipe bending applications
• FAQs

Pipe bending tools

There are many types of pipe benders, and choosing the best bending tool depends on the application and budget. For example, a manual pipe bender will almost always cost less than an electric or hydraulic pipe bender. However, electric pipe benders are ideal for mass production, and hydraulic pipe benders are suitable for bending pipes made of stronger materials.

When looking for a pipe bender, pay attention to tube bending tools as well. The difference between tubes and pipes is that a tube’s size is measured by its outside diameter, and a pipe’s size is measured by its inside diameter and wall thickness. Therefore, the difference between pipe bending and tube bending tools is more about terminology than functionality.

Manual pipe benders

A hand-bending tool is budget friendly and ready to operate quickly. There are several tools for manual bending; refer to our manual pipe bender article for further information.

• Dual pipe bender: A dual pipe bender (Figure 2) has two handles that a user pushes together to bend the pipe. The pipe bends around the pipe bender die (the component determining the bend's inside radius). Therefore, the material that can be bent depends on the user's strength. Aluminum and plastic pipes are much easier to bend than steel and cast iron pipes.
• Mini and macro pipe benders: These manual pipe benders apply to smaller diameter pipes and tubes. A mini pipe bender bends 6 - 10 mm pipe, and a macro bender bends pipe with a diameter smaller than 6 mm.
• Conduit pipe bender: Conduit is metal piping that protects wires and cables from damage. A conduit bending tool requires one hand to operate, using the floor or a flat surface to provide leverage. Longer handles are available for these benders to bend stronger pipes, such as steel pipes. Bending of conduit can damage wires and cables if they are inside the conduit during the bending process.
• Ergonomic pipe bender: An ergonomic pipe bender is similar to a dual pipe bender. However, it has long, curved handles, requiring less force from the user to bend the pipe. This bender is suitable for 10 - 15 mm diameter pipes.
• Free-standing pipe bender: This pipe bender is the largest of manual pipe benders. It has a long handle that can be operated with both hands to provide the force necessary to bend stronger pipes.
• Ratchet pipe bender: A ratchet pipe bender has a lever that pushes the die, or pipe former, against the pipe to make the bend. This pipe bender is suitable for up to 90° bends and 10 - 32 mm diameter pipe.

Electric pipe benders

Advances in electronics allow for accurate and fast pipe bending. Electronic pipe benders, also known as pipe bender machines, range from semi-automatic to fully automatic operation. Basic pipe bending machines allow users to input the bend angle into the user interface, and the machine will bend the pipe to that precise angle. More advanced electric benders also reorient the pipe during the process to provide pipe bending along different planes. Most pipe bender machines have the following parts:

• Bend die: The bend die controls the inside radius of the bend.
• Pressure die: The pressure die ensures that the tube follows the bend die’s contour.
• Clamp die: The clamp die stops the tube from slipping off the bend die.
• Wiper die: The wiper die goes after the bend die and prevents bumps forming on the inside radius.
• Mandrel: A mandrel is necessary for difficult bending jobs: small radii, thin tubes, or hard material like steel. The purpose of the mandrel is to prevent pipe collapse during bending.

There are several types of electric pipe bending machines. To learn more, read our electric pipe bender article. Common electric pipe bending machines are:

• Rotary-draw: The pipe is clamped against the bend die, which rotates along its axis, pulls and bends the pipe to the desired bend angle.
• Roll bending machine: Also known as 3-roll benders, roll bending machines (Figure 3) are ideal for large radius bends.
• Induction bending machine: This bending machine uses an induction coil at the bending point, heating the pipe for easier bending.
• CNC pipe bending machine: CNC pipe bending machines only require a user to place the pipe in the machine and input instructions. The instructions detail where to bend the pipe, the pipe bend angle, and the orientation of the pipe. An example of this is the vector tube bending machine, which automatically feeds the pipe to the die for bending.

Hydraulic pipe benders

Hydraulic pipe benders operate similarly to manual ratchet benders. A die presses the pipe against two stationary points to achieve the bend. These benders are ideal for bending stronger pipes, such as steel and cast iron. A user needs less force to bend strong pipes because hydraulics utilize non-compressible fluid to achieve force multiplication. Learn more about hydraulic pipe benders by reading our article on the topic.

The user pushes a lever to move the die forward, and the stationary points are adjustable to control the bend of the angle. There are two types of hydraulic pipe benders:

• Vertical hydraulic pipe bender: As seen in Figure 4, a vertical hydraulic pipe bender is supported by a metal stand. Pulling the bender’s lever moves the die upward, pushing the pipe against the stationary points.
• Horizontal hydraulic pipe bender: A horizontal hydraulic pipe bender can sit on the floor or a work table. Typically, this bender has wheels attached to one side, making it more portable.

Pipe bender pros & cons

As discussed above, each type of pipe bender has pros and cons. Table 1 summarizes the pros and cons of each type.

Table 1: Pipe bender types comparison

Type	Pros	Cons
Manual	Budget-friendly Readily available to operate	Not suitable for bending pipes made from strong metals (e.g., steel and cast iron) Excessive human effort required Less precision than electric benders
Electric	Automation allows for more precise and faster pipe bending and, therefore, mass production of bent pipes	Very expensive Requires a lot of space
Hydraulic	Small and safe to use Allows for bending of hard metals like steel and cast iron	Takes time to set up the machine for use

Pipe bending methods

Ideally, the correct pipe bending method is chosen based on the pipe's characteristics (e.g., diameter, wall thickness, and material). However, the available pipe bender will also determine which method is used because different pipe benders use different methods.

• Ram bending: The manual ratchet pipe bender and hydraulic pipe benders use this method. A die is pressed against a pipe fixed in place by two stationary points. This cost-effective bending method does not give as much control over the bend.
• Rotary draw bending: Electric pipe benders use this method. A pipe is fixed against the die, which rotates and pulls the pipe, bending it in the process. This method provides a high-quality finish.
• Compression bending: Compression bending is similar to rotary draw bending but does not use a mandrel in the tube. This method is used when slight deformations are allowable. Compression bending favors speed and high output.
• Mandrel bending: Mandrel bending is the same as rotary draw bending, except for the addition of a mandrel within the pipe during the bending process. This helps maintain the smooth finish with small radius bends or bending of pipes with thin walls.
• Roll bending: The electric roll bender discussed above uses this method. This method works well with large circumference pipes and produces even cross-sections with minimal deformation.

Pipe bending applications

There are countless applications for pipe benders. The following detail some of the most common applications for manual, electric, and hydraulic pipe benders.

• Manual: Manual pipe benders do not have much industrial application due to their relative imprecision and necessary time to use. They are, however, often used by DIY users for roll cages, custom furniture frames, and ornamental purposes.
• Electric: Electric pipe benders are ideal for industrial production of handrails, automotive roll cages, handles, and pipe coils. They are also used in the aerospace and automotive industries.
• Hydraulic: Hydraulic pipe benders have similar applications as manual pipe benders, except they are easier to operate and can bend pipes made of stronger materials.

FAQs

What is the difference between a pipe bender and a tube bender?

There is not a significant difference between pipe and tube benders. The difference lies in the classification of pipes and tubes. The former is measured by wall thickness and inside diameter, while the latter is measured by outside diameter.

What does a pipe bender do?

A pipe bender bends pipe, which is less expensive than welding different pipes together or creating other types of connection points to change the direction of the piping.