Pipe Bending (Cold and Hot)

Pipe bending forms curves in pipework to change direction without using fabricated fittings or elbows.
Cold bending uses hydraulic or mechanical benders to form bends in steel, copper, and plastic pipes.
Hot bending heats the pipe with oxy-fuel torches or induction coils before forming the bend.
Incorrect bending causes pipe wall thinning, wrinkling, and ovality that weaken the section permanently.
Hydraulic pipe benders generate enormous forces; hands and fingers near the forming die are crushed instantly.
Hot bending requires hot works controls including permits, fire watches, and fume extraction.
Spring-back in steel pipes releases stored energy when the bender is opened, throwing the pipe end.
Induction bending uses high-power electrical coils; electrocution and burn risks require strict controls.
The pipe specification sets minimum bend radii; tighter bends cause unacceptable wall thinning.
PUWER 1998 requires bending equipment to be maintained, guarded, and operated by trained personnel.

Crush injuries	Hydraulic benders generate forces that crush hands, fingers, and arms trapped between the pipe and forming die.
Burn and fire risk	Hot bending with torches and induction heaters creates burn hazards and fire risk from heated pipe and equipment.
Pipe failure	Incorrect bending causes wall thinning and defects that fail under pressure, causing leaks and catastrophic bursts.

Do

Don't

Check the pipe specification for minimum bend radius before starting.
Keep hands and body clear of the forming die during hydraulic bending.
Obtain a hot works permit before using torches for hot bending operations.
Use induction bending equipment only with proper electrical safety controls.
Inspect the bent pipe for wall thinning, wrinkles, and ovality after forming.
Secure the pipe firmly in the bender before applying hydraulic pressure.
Wear heat-resistant gloves and face protection during hot bending operations.
Allow hot-bent pipes to cool naturally; do not quench with water unless specified.
Use fume extraction when hot bending produces visible fume or smoke.
Train all operators on the specific bending equipment before they use it.

DON'T place hands near the forming die while the hydraulic bender is pressurised.
DON'T bend pipe tighter than the minimum radius specified for that material.
DON'T hot bend without a hot works permit and fire watch in place.
DON'T stand in the spring-back path when releasing the pipe from the bender.
DON'T use the bent pipe if inspection shows wall thinning beyond specification limits.
DON'T leave hot-bent pipe where it can burn others who may not realise the temperature.
DON'T force a pipe into the bender; it should fit the die without excessive force.
DON'T use damaged or worn bending dies that mark or deform the pipe surface.
DON'T operate hydraulic benders without training on the specific equipment model.
DON'T skip the post-bend inspection; defects are hidden on the inside of the curve.

See also: Pipeline Safety Awareness | Pipe Cutting On Site

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