Barnshaws Induction Bending - An Advanced Metal Bending Process

03/02/2018 Barnshaws Induction Bending - an Advanced Metal Bending Process
HOME / SERVICES / INDUCTION BENDING
INDUCTION BENDING
Induction bending by Barnshaws is an advanced metal bending
process, offering optimum precision, efficiency and consistency. It is
suitable for a very wide range of applications and completely
overcomes the potential limitations of cold bending techniques, such
as distortion and wall thinning.
Straight pipe, tube or other section types are placed on a machine bed
with a swing arm set to the required radius. The material is then
hydraulically pushed through an induction coil at a carefully controlled
and monitored rate. Heat of approximately 1000°C is solely focused on
the area which requires bending, while cool air and water is sprayed
on the area adjacent to the heated zone.
The combination of speed, heat and cooling allows sections to be

bent to tighter radii without cross sectional deformation.
Typical application sectors:
Power generation – Construction – Ship building – Offshore oil and

gas – Petrochemicals – General fabrication
http://www.barnshaws.com/services/induction-bending/detail 1/16
INDUCTION BENDING
I N F O R M AT I O N
C A PA B I L I T Y A N D C A PAC I T Y
At Barnshaws, we offer a uniquely comprehensive induction bending

service, providing the following decisive advantages: -
Induction pipe bending from 50.8mm (2”) to 813mm (32”)

O/diameter, using material up to 50mm thickness.
Pipe and other sections can be curved to smaller radii than with
cold bending techniques.
Pipe surface unaffected/unblemished by the process.
Multiple bends possible on a single length of pipe.
Reduced welding requirement with compound bends, improving

finished pipework integrity.
Faster and more energy efficient than traditional fire/hot slab

bending methods.
A completely controlled and recorded process.
Certification available, describing all key aspects of the

induction bending process at a component-specific level, if
required.
To ensure the most cost effective and efficient material usage, we

provide a material utilisation pre-order analysis. This assists our
customers in achieving unrivalled competitiveness and giving them a
true edge in the markets they serve.
We can bend pipe from 50.8mm (2”) to 813mm (32”) O/diameter, using
material up to 50mm thickness.
Barnshaws has also amassed a wealth of expertise in bending

construction beams and 500 x 300 RHS, using this highly capable and
versatile technique.
We induction bend with the following materials (list not exhaustive): -
Carbon steel – Alloy Steel (low, medium, high), Chrome, molybdenum

steel – Case hardened and tempered steels – Heat resistant and high
temperature steels – Low temperature steels – Stainless steel and
acid resistant steel – Super Duplex stainless steel – Clad carbon
steels (internally clad), Tubes and pipes, either seamless or welded.
Types of bend include: -
Quarter 90o bend – Angle bend 0-120o – SHS up to 400 x 400 x 20 –

Cross over bend – S-bend/offset bend – RHS bent about minor axis
up to 500 x 300 x 20 – Curved tube up to 813 – Elliptical tubes (minor
and major axis) – Universal beams
Our full range of post manufacturing processes, associated with

induction bending, includes: -
Weld preparation – Hydrostatic pressure testing – Heat treatment and

cleaning – Coating and surface treatments – In house/third party
inspections as applicable, inc. NDT testing – Mechanical and non-
destructive testing.
PRODUCT RANGE
Our 120,000 sq. ft. purpose built manufacturing facility houses 25

overhead cranes with a maximum lifting capacity of 20 tonnes. Our
induction bending machines enabling us to bend from 2"NB to 32"OD.
We can accommodate wall thicknesses from 2mm through to 50mm.
Materials suitable for Induction Bending include: -
Carbon steels including API 5L Gr. B / ASTM A106 Gr. B

Case hardened and tempered steels
Duplex & Super Duplex steels, including 22% Cr (UNS S31803)

and 25% Cr (UNS S32750 / 60)
High chrome materials, inc. ASTM A335 P11, P22 & P91 etc.
High yield steels - API 5L X42 to X80 (inc. internally clad steels)
Low temperature materials, such as ASTM A333 Gr.6
Specialist steels, including AISI 4130, Inconel, Hastelloy & Ovako

280®
Stainless steels – ASTM A312 304L, 316L, 321 etc.
Tubes and pipes, either seamless or welded
We can also carry out the following operations: -
End Beveling
Chemical cleaning, pickling & passivation
Cutting of up to 32″ OD round sections
Destructive mechanical testing using our UKAS accredited

laboratory partner
Non destructive testing carried out by ASNT / PCN level II

approved operators
HOW DOES INDUCTION BENDING

WORK?
Induction bending is an advanced metal bending process, offering

optimum precision, efficiency and consistency. It is suitable for a very
wide range of applications and completely overcomes the potential
limitations of cold bending techniques, such as distortion and wall

thinning.
Straight pipe, tube or other section types are placed on a machine bed
with a swing arm set to the required radius. The material is then
hydraulically pushed through an induction coil at a carefully controlled
and monitored rate. Heat of approximately 1000°C is solely focused on
the area which requires bending, while cool air and water is sprayed
on the area adjacent to the heated zone.
The combination of speed, heat and cooling allows sections to be

bent to tighter radii without cross sectional deformation.
The machinery design ensures there are no limitations on the length

of pipe used. The heat band eliminates the risk of pipe wrinkling and
normal bending is carried out without the use of mandrels or formers,
thanks to the robust support provided through the cooled pipe on
either side of the narrow heated section.
Induction heating affords high speed and efficiency and enables very
accurate temperature control (+ or - 30 degrees C). Pipes do not
develop scaling during the process and even previously scaled
material can still be bent as efficiently as pipe or tube in perfect
condition. This remarkable flexibility also extends to previously rusted,
seam, butt or spiral welded material.
Varying material wall thickness can also easily be accommodated,

using appropriate machinery adjustments during manufacture.
A D VA N TA G E S O F U S I N G I N D U C T I O N
BENDING
Infinitely variable bend radius, offering optimum design

flexibility.
Superior quality in terms of ovality, wall thinning and surface

finish.
Avoids the need for components with an elbow, allowing

cheaper, more readily available straight materials to be utilised.
A stronger end product than elbows with a uniform wall

thickness.
Large radius bend capability reduces friction and wear.
Surface quality of bent material is not relevant in terms of

suitability for use.
Quicker production times than the welding of separate

components.
No cutting, rounding-up, match boring, fitting or heat

treating/welding of forged fittings.
Pipe and other sections can be curved to smaller radii than with
cold bending techniques.
Material surface unaffected/unblemished by the process.
Multiple bends possible on a single length of pipe.
Reduced welding requirement with compound bends, improving

finished pipework integrity.
Welds avoided at critical points.
Less need for non-destructive testing, driving costs further

down.
Faster and more energy efficient than traditional fire/hot slab

bending methods.
Process eliminates the need for sand filling, mandrels or

formers.
A clean, lubricant-free process.
Bend specification changes are possible right up to the last

minute before production.
Reduced need for formal on-site inspection of welded joint

integrity.
Faster repair and maintenance lead times, due to relative ease

of producing replacement induction-bent pipes or tubes.
T E C H N I C A L I N F O R M AT I O N
OVALITY
Standard Wall Carbon Steel
Capacity
Barnshaws Group can bend pipe up to 813mm (32") outside Diameter.
THINNING
Standard Wall Carbon Steel
Capacity
Materials we can bend include:
Carbon Steel
Alloy Steel (low, medium & high alloy)
Chrome, Molybdenum Steel
Case Hardened & Tempered Steels
Heat Resistant & High Temperature Steels
Low Temperature Steels
Stainless Steel & Acid Resistant Steel
Super Duplex Stainless Steel
Clad Carbon Steels (Clad Internally)
Tubes & Pipes can be Seamless or Welded
TYPES OF BEND
BARNSHAWS’ EXPERIENCE
We have been deeply involved in induction bending since 1999. Since

then we have amassed a vast amount of experience in all types of
projects and applications.
Barnshaws' capacity range includes tubes up to 32" (813mm),

rectangular hollow section up to 500 x 300, square hollow sections up
to 500 x 500, beams up to 610 wide and channels up to 430 wide. No
other company in the world offers such a range of sections / unusual

forms.
The Barnshaws induction bending service is audited by BSI to the

ISO9001-2008 standard. We work with SCCS on many pipe bending
projects for third party approval.
Our in-house testing facilities include, ultrasonic thickness checking,

surface hardness testing of the bend area and ovality / dimension
reports and X-ray analysis.
Standard service for induction bending is 10 working days for small

batches. No company can offer the same speed of turn around.
CE MARKING
Barnshaws is the first metal bending company in the UK to have

achieved total compliance with En1090-1; Requirements for conformity
assessment of structural components, covering the supply of curved
components to Execution Class 4 (Exc4). All our induction bent
products are therefore fully CE marked for traceability.
Successfully assessed by SCCS, Barnshaws is able to assure

customers that it has systems in place to ensure that all materials used
in manufacture are correct for purpose, with a traceable audit path and
that the Barnshaws product in question is fully compliant with its
expected end use.
The CE Mark also confirms the competence, knowledge and skills of

manufacturing staff and that manufacturing equipment is properly
maintained and calibrated (where necessary).
Barnshaws invested a six-figure sum to achieve accreditation.

Particular emphasis was placed on both the tensile and yield strength
of products in the performance assessment of every aspect of the
product range, using hundreds of samples fabricated to a variety of
different radii.
The company has involved its entire supply chain in the CE Marking
process, to ensure that all product components acquired from third
parties are in full compliance in terms of measurement and

performance.
All of Barnshaws’ five UK operations have been audited by SCCS

during the accreditation process.
POST BENDING TREATMENT
An inherent feature of induction bending is that mechanical properties

may be altered – on occasions significantly - due to the heat input
allied and the stresses applied during the process.
Most materials that have been induction bent by Barnshaws, in

particular high yield carbon & duplex type steels, will therefore need a
full body furnace heat treatment after bending in order to restore or
improve mechanical properties.
We offer the following post bending heat treatment services: -
Normalise
Most typically used for carbon steels such as ASTM A106 Gr. B, A333
Gr. 6 & API 5L X52, the normalising process involves a set time at
temperature with a still air cooling to the ambient temperature away
from the furnace area.
Normalise & Temper
Most usually applied to materials with a higher level of chrome e.g.

ASTM A335 P11 & P22 etc. First we normalise the material, following
this by tempering it for an extended period at a lesser temperature,
again utilising still air cooling to the ambient temperature.
Quench & Temper
This post bending process is for high yield materials e.g. API 5L X65.
We hold the material at temperature for a specified time. It is then
quickly quenched in an appropriate cooling medium. This promotes a
hardening action. We follow this by tempering at a reduced
temperature with still air cooling to the ambient temperature.
Solution Anneal
A process that can be applied to stainless & duplex steels such as

UNS S31803 & UNS S32760. We hold the material at a heightened
temperature for a specified time. We then carry out a rapid cooling
technique, using either air or water. Secondary heat treatment is
generally not needed.
APPLICATIONS
The numerous advantages of the induction bending process are now

widely recognised and deployed across a diverse range of industries.
Induction bent pipes and tubes are typically used for anything from a
large scale conduit to heat exchange and movement of a plethora of
liquids and gases.
Bending by Barnshaws for structural applications meets N.S.S.S

tolerances and conforms to ASME standards for petrochemical
applications.
This remarkable application flexibility means that we are able to

provide a full service to a wide range of industries, including (but not
limited to): -
Chemical
Nuclear
Compressor and pump stations - fluids and gases
Construction
General & Process Pipework
Offshore Oil & Gas Production - subsea/topside
Power Generation
Petrochemical
Shipbuilding
We would stress that new applications are being developed all the
time. Please don't hesitate to contact us today to discuss how we can
help you to deliver the many benefits of induction bending in new,
innovative ways.
T E C H N I C A L I N F O R M AT I O N
OUR MISSION
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W H E N Y O U N E E D I T.
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TOGETHER.
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03/02/2018 Barnshaws Induction Bending - an Advanced Metal Bending Process

HOME / SERVICES / INDUCTION BENDING

The combination of speed, heat and cooling allows sections to be

Typical application sectors:

Power generation – Construction – Ship building – Offshore oil and

At Barnshaws, we offer a uniquely comprehensive induction bending

Induction pipe bending from 50.8mm (2”) to 813mm (32”)

Pipe surface unaffected/unblemished by the process.

Multiple bends possible on a single length of pipe.

Reduced welding requirement with compound bends, improving

Faster and more energy eﬃcient than traditional ﬁre/hot slab

A completely controlled and recorded process.

Certiﬁcation available, describing all key aspects of the

To ensure the most cost effective and eﬃcient material usage, we

Barnshaws has also amassed a wealth of expertise in bending

We induction bend with the following materials (list not exhaustive): -

Carbon steel – Alloy Steel (low, medium, high), Chrome, molybdenum

Types of bend include: -

Quarter 90o bend – Angle bend 0-120o – SHS up to 400 x 400 x 20 –

Our full range of post manufacturing processes, associated with

Weld preparation – Hydrostatic pressure testing – Heat treatment and

Our 120,000 sq. ft. purpose built manufacturing facility houses 25

Materials suitable for Induction Bending include: -

Carbon steels including API 5L Gr. B / ASTM A106 Gr. B

Case hardened and tempered steels

Duplex & Super Duplex steels, including 22% Cr (UNS S31803)

Low temperature materials, such as ASTM A333 Gr.6

Specialist steels, including AISI 4130, Inconel, Hastelloy & Ovako

Stainless steels – ASTM A312 304L, 316L, 321 etc.

Tubes and pipes, either seamless or welded

We can also carry out the following operations: -

Chemical cleaning, pickling & passivation

Cutting of up to 32″ OD round sections

Destructive mechanical testing using our UKAS accredited

Non destructive testing carried out by ASNT / PCN level II

HOW DOES INDUCTION BENDING

Induction bending is an advanced metal bending process, offering

limitations of cold bending techniques, such as distortion and wall

The combination of speed, heat and cooling allows sections to be

The machinery design ensures there are no limitations on the length

Varying material wall thickness can also easily be accommodated,

Inﬁnitely variable bend radius, offering optimum design

Superior quality in terms of ovality, wall thinning and surface

Avoids the need for components with an elbow, allowing

A stronger end product than elbows with a uniform wall

Large radius bend capability reduces friction and wear.

Surface quality of bent material is not relevant in terms of

Quicker production times than the welding of separate

No cutting, rounding-up, match boring, ﬁtting or heat

Material surface unaffected/unblemished by the process.

Multiple bends possible on a single length of pipe.

Reduced welding requirement with compound bends, improving

Welds avoided at critical points.

Less need for non-destructive testing, driving costs further

Faster and more energy eﬃcient than traditional ﬁre/hot slab

Process eliminates the need for sand ﬁlling, mandrels or

A clean, lubricant-free process.

Bend speciﬁcation changes are possible right up to the last

Reduced need for formal on-site inspection of welded joint

Faster repair and maintenance lead times, due to relative ease

Standard Wall Carbon Steel

Barnshaws Group can bend pipe up to 813mm (32") outside Diameter.

Standard Wall Carbon Steel

Materials we can bend include: