Custom Pipe and Tube Bending
We provide induction, roll and rotary pipe and tube bending for industrial, commercial, recreational and architectural applications.
We specialize in round, square and rectangular shaped steel, stainless steel, brass, bronze and aluminum pipe and tubing. Short tangent or full-length multiple bend capabilities are also available.
Rotary Bending is accomplished by bending the pipe or tube on a fixed die set machined to fit the exact outside diameter. A mandrel is inserted inside the pipe or tube to prevent collapse during the bending process. Wagner can rotary bend most materials up to 4.50″ OD to a maximum of 180 degrees of bend. Square and rectangular materials can also be bent. Our CNC bending equipment allows for high-quality repeatability. Multiple bend configurations can be produced, greatly reducing the amount of welding and polishing required.
Here are the specs for our roll bending capabilities:
- Pipe sizes: 3/4″, 1″, 1-1/4″, 1-1/2″, 2″, 3″ and 4″.
- OD tubing sizes: 1.25″, 1.50″, 2.00″, 2.50″, 3.00″, 3.50″, 4.00″, 4.50″ and 5.00″.
- Square and rectangular tubing sizes: 3/4″ through 3″ – Easy Way or Hard Way – see Rotary Bending.
- Structural angles and channel.
When specifying roll bending, the following information is required:
- Center Line Radius (CLR) and Angle or
- Center Line Radius (CLR) and Arc Length or
- Chord and Height
The dimensions listed above all reference the centerline of the bend. You may also provide dimensions based on the inside or outside radii as long as the reference radii are consistently used.
Minimum tangent lengths required are:
- 8″ each end up through 2″ pipe size – 2.375″ diameter
- 18″ each end for material larger than 2″ pipe.
The arc length is limited by the stock length of material less the minimum tangent lengths. When possible, all like radii bends are combined and rolled as one larger length then split after rolling.
Induction Bending is accomplished by heating the material and forcing the bend to a preset radius. Since no special tooling is required, induction bending is a precise and cost-effective method of custom bending pipe or tube for architectural, industrial, commercial and specialty applications in small or large quantities.
- Bend any center line radius between 12″ and 48″.
- For tube sizes from 1.50″ through 5.00″ OD.
- Wall thicknesses of .120″ or greater work best.
Open-end feeding systems allow for one-pass bending of short sections or lengths to 21’. High accuracy in bending produces radii and degree-of-bend within 1/8″ tolerance for the overall length.
We can perform successive or a series of bends with changes of plane in one pass on a single section of pipe or tube. Tolerances in radii may be as little as .10″. Unlike cold bending, our induction method does not require the use of costly dies, clamps, wipers and mandrels.
MATERIALS & SHAPES
Wagner is equipped to bend steel, stainless steel, brass alloys and aluminum to standard or customized shapes as you require. Contact Wagner early in your design process so that we can discuss how our induction bending technology can save you money and material. We offer you custom bending in small quantities and in any radius between 8.5″ and 48″ centerline without tooling charges. Our unique bending capabilities hold sizes within 5%.
Wagner can produce sweeping rail returns – sweeps – to your specifications. These sweeps greatly reduce the time spent by fabricators in the field while providing the quality look of a true sweeping elbow. Such elbows are recommended by ICC/ANSI A117.1 and the ADAAG which state that “continuous, inside handrails on switchback or dogleg stairs can indicate to the person with a visual impairment that another stair flight begins immediately after the turn.” When specifying these sweeps, use the templates shown below and submit the pipe or tube size and the dimensions as noted.
ROLLING A HELIX
In a true helix, the material is twisted. Roll Bending operates only in one plane and therefore Wagner cannot actually roll a helical bend. However, we have found that on larger centerline radii – 15′ and above – we can calculate a radius bend that will lay flat on the floor but that can be tilted up into place to meet the requirement.
RADIUS VS. DIAMETER
Bend radii and diameters will refer to either the inside or center line of a bend. There is often confusion between radius versus diameter. Note in the diagram below that the diameter is two times the radius. Therefore a 180º bend on a 7″ center line radius would yield a 14″ center line diameter (14.00″ center-to-center). The inside radius (r) is equal to the center line radius (R) less half the OD or width of the tubing being bent.
CUSTOM TO SPEC
- Fifteen Rotary Draw Benders thru 4″ Sch. 80 Pipe (4.50″ OD)
- VB300 Eaton Leonard CNC 3″ Rotary Bender
- VB400 Eaton Leonard CNC 4″ Rotary Bender
- Crippa CA-1042 E, Automatic CNC Tube Bending Machine
- Two Elva Induction Benders through 5.00″ OD, 1/4″ Wall
- Unison CNC Rotary Draw Bender thru 2.50″ OD, .065″ Wall
- Four RAM Benders from 3T-30T (Vertical Press Bends)
- R-3 Roundo Roll Bender – 11/2″ Sch. 80 Pipe (1.900″ OD)
- R-6S Roundo Roll Bender – 4″ Sch. 80 Pipe (4.50″ OD)
- Two Buffalo Roll Benders
- Six Cold Saws
- Seven Band Saws
- Six Tube End Forming Machines
- Three Auto Feed Band Saws
- Two Pipe Belt Copers
- Milling Pipe Coper
Wagner can bend most pipe schedules and tube gauges. Please contact Wagner with your special requirements. For custom bending, quotes will indicate the Wagner Tolerance Class used for each quote. Please indicate if dimensions have critical tolerances. Quotes can be based on a tighter tolerance class. The details that follow are common shapes for pipe and tube that may be bent from existing tooling. When describing your bend requirements, provide Wagner with the noted dimensions and the SK style number for pricing.
These configurations are available in most pipe and tube sizes, all materials and most standard radii. See here for a partial list of available tooling.