Construction profiles come in a wide variety. Kersten uses extensive, modern machinery to bend standard construction profiles and customer-specific sections. We use cold and induction bending methods in order to bend 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 curved product, the profile is bent 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.
Induction bending is a very efficient and precise bending technique using heat in order to bend tubes, pipes and sections. It takes over where cold bending methods meet their limitations. The combination of speed, local heat and cooling allows for bending even bigger profiles. Pipes up to Ø914 x 50mm and standard structural sections of up to 1100mm.
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.
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
- Hot bending by induction for even bigger pipes and sections
- 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