Guide to Induction Bending

Contents

1. Introduction to Induction Bending
2. Proclad's Expertise in Induction Bending
3. Induction Bending Process
4. Materials and Capabilities
5. Applications Across Industries
6. Advantages of Induction Bending
7. Quality Assurance and Innovations
8. Conclusion

‍

1. Introduction to Induction Bending

Induction bending is an advanced metal forming technique that uses localized heating through electromagnetic induction to precisely bend pipes and structural components. This method ensures minimal deformation and maintains the integrity of the material, making it ideal for complex bending requirements.

2. Proclad's Expertise in Induction Bending

Established in 1985 as Induction Bending Services Ltd (IBS), Proclad Induction Bending has grown to become the UK's leading induction bending company. With a fleet of five bending machines, we handle diameters ranging from 2 to 42 inches, catering to diverse project needs. Our acquisition by the Proclad Group in 2001 has further enhanced our capabilities, allowing us to efficiently manage contracts of all sizes.

‍

3. Induction Bending Process

The induction bending process involves several critical steps to ensure precision and quality:

1. Preparation: A straight pipe is loaded into the bending machine and clamped to the bending arm at the required bend radius.
2. Heating: Induction power is applied, and when the required temperature is achieved, the pipe is driven forward at a controlled speed to initiate bending.
3. Bending: The bending arm provides the bending moment to curve the pipe at the clamped radius, progressing in a continuous, even process until the desired bend angle is achieved.
4. Cooling: Cooling is applied immediately after bending to set the bend.

Advanced process control over principal manufacturing parameters—temperature, speed, and cooling rate—is essential to achieve consistent and acceptable results.

4. Materials and Capabilities

Proclad's induction bending services accommodate a wide range of materials, including:

• Carbon steel
• Low alloy steels
• Stainless steels
• Duplex and super duplex steels
• Clad materials

Our bending capabilities include:

• Pipe diameters from 2 inches (50mm) to 42 inches (1050mm)
• Pipe thicknesses ranging from 0.25 inches (6mm) to 4 inches (100mm)
• Manufacturing bends up to 180 degrees
• Achieving multiple bends and swirls on a single length of pipe

These extensive capabilities enable us to meet diverse project specifications across various industries.

5. Applications Across Industries

Induction bending is utilised in numerous sectors, including:

• Oil and Gas: Fabrication of pipelines and risers
• Power Generation: Construction of boiler tubes and steam lines
• Renewable Energy: Formation of structural components for wind turbines
• Chemical Processing: Development of process piping systems
• Nuclear: Creation of cooling system pipelines

The precision and efficiency of induction bending make it suitable for applications requiring large-diameter bends with high accuracy and reliability.

‍

6. Advantages of Induction Bending

Induction bending offers several benefits over traditional cold bending techniques:

• Precision: Achieves tight radii and accurate angles with minimal deformation
• Efficiency: Reduces the need for welding by enabling multiple bends on a single pipe length
• Material Integrity: Maintains wall thickness and minimizes ovality
• Versatility: Applicable to various materials and cross-sectional shapes

These advantages result in cost savings and improved structural integrity for complex piping systems.

7. Quality Assurance and Innovations

At Proclad, quality is paramount. Our Intelli-Bend 2.0 Automatic Temperature Control (ATC) system offers full automation of the pipe bending process, ensuring 100% repeatability and quality control in every bend. This innovation positions us among the few companies worldwide capable of guaranteeing such precision.

‍

Additionally, we provide comprehensive support services, including:

• In-house heat treatment solutions
• Mechanical testing
• Coating
• Fabrication
• Shot blasting

These services are designed to offer clients a seamless, turnkey solution for their bending requirements.

‍

8. Conclusion

Proclad's induction bending services combine advanced technology, extensive capabilities, and a commitment to quality, making us a trusted partner for complex bending projects across various industries. Our expertise ensures that we deliver precise, efficient, and cost-effective solutions tailored to meet the unique needs of each client.

‍