Construction profiles come in a wide variety. Kersten uses extensive, modern machinery to bend standard construction profiles and customer-specific regular or rolling profiles. The flagship of the fleet is Europe's largest and heaviest profile bending machine. This powerful machine rolls profiles of up to 1,000 mm and pipes of up to Ø610 mm. The wide range of machines makes it possible to curve a large variety of types and sizes in almost any desired radius, taking into account specific (tolerance) requirements.
Profiles can be bent in 2D and 3D. Kersten has developed a specialization in the 3D curving of light and heavy profiles, where the profile, as well as a radius, also has a gradient. This technique used to build stairs, art objects, industrial mixers, and in building tracks for roller coasters amongst other things
Depending on the profile properties, the radius and the application of the bent product, the profile is curved according to one of the following bending techniques:
A complete series of profile rolling machines is used for rolling profiles. Kersten Europe rolls profiles of 80 to 1.000 mm and pipes and tubes from Ø 10 to Ø 610 mm.
No product specific tooling is required for rolling and the machine does not have to be converted for a specific profile to be bent in various radii. This makes rolling cost technically very interesting.
Excess length is always required for rolling. However, this can be limited by a smart material classification. We will gladly advise you on this.
The following animation shows the rolling process of a tube. You can see the tube being rolled in the machine and how the additional bending allowance is determined. This is then removed automatically, leaving the tube with a 3D cut contour for optimal tube-to-tube connection.
Mandrel bending is a good solution for curving thin walled profiles in a very small radius. Compared to rolling, a much smaller radius can be achieved. However, this curving technique requires product specific equipment to protect the profile from the tearing and distorting that can occur during bending in a small radius.
The equipment does mean that start-up costs are relatively high and therefore less appealing when dealing in smaller quantities. However, equipment for standard construction profiles are often already available. For these standard profiles and/or larger series mandrel bending is ideal. It is quick, extremely efficient and delivers constant quality.
This extremely accurate technique comes from the aviation industry, but is increasingly used within architecture. Stretch bending is the ideal technique when the surface quality of the profile is very important. For example aluminium façade profiles and aerofoils.
This bending process uses a special machine that clamps the profile at both ends, tensions it and then pulls it around a mould. In contrast to rolling, the profile does not come into contact with the machine, whereby the surface of the material remains in perfect condition. The constant tension on the profile cross-sectional deformation is kept to a minimum.
Profile bending at a glance
- Cold bending of steel, stainless steel and aluminium profiles
- Complete series of standard construction profiles: varying from UNP 80 up to and including HEA 1000
- Bending of various dimensions of pipe, beam and hollow profiles with small radii
- Rolling of customer-specific set or roll form profiles
- 3D bending of light and heavy tubes and profiles