1. Unit 204: Common Plumbing Processes
Outcome 1.1 – 1.4
Procedures for bending 90°bend in 15mm Copper Tube

2. Unit 204: Common Plumbing Processes
Aims
To manufacture a 90⁰ bend in 15mm copper tube –
{TASK P5 – Copper tube bending 1 [P34 – 6035 practical task manual]}
Objectives
Identify the tools required to complete 90° bend in 15mm copper tube
Complete a drawing of 90° bend in 15mm copper tube to a scale of 1:1
Manufacture a 90° bend in 15mm copper tube to ±3mm and ±3°
Present final 90° bend in 15mm copper tube to be assessed by peers and tutor

3. Measuring and bending tubes
Task P5
15mm = D
300mm
15mm = D
150mm (Y axis)
60mm
30°
125mm
(Y axis)
90°

4. Measuring and bending tubes
The units of measurement plumbers use are: Millimetres = mm Metres = m 1,000mm = 1m

5. Measuring Tools Rules and tape measures
Steel rule: for accurate pipework measurement
and bending
Tape measure: pipework installation or measuring
longer pipe lengths

6. Bending Tools Bending Machines Microbore hand bender:
R220 soft coiled copper 6,8,10mm
Hand bender:
R250 half hard copper 15 and 22mm
Stand bender: R250 half hard copper 28 and 32mm

7. Bending Tools
Bending Springs
Internal and external springs

8. Measuring and bending tubes
Engineers square
Tools Required
Hand bender and guides
Steel rule: for accurate pipework measurement
and bending
Pencil
Set Squares

9. Measuring and bending tubes
22.50
450
900

10. Measuring and bending tubes
Golden rules
Select the measuring method:
Centre to centre
Centre to Back
Measure twice, cut once or bend once.
If a section needs two or three bends, ensure the first bend is correctly positioned in the bender before pulling the second.

11. Measuring and bending tubes
Golden rules
Where possible, work from a fixed point to avoid cutting to length.
The measured end of the pipe always goes into the bender
– waste to waist.
Always mark the throat of the bend.

12. Task 1
Please draw and complete a 90° bend in 15 mm pipe with a 125mm (Y axis) and a 150mm (X axis)
{TASK P5 – Copper tube bending 1 [P34 – 6035 practical task manual]}

13. Measuring and bending tubes
Task 1
150mm (X axis)
15mm = D *
C = 150mm - 4 x D
125mm
(Y axis) B
= 4xDx½π
A = 125mm – (4 x D) = 125mm – 60mm =
B = 4 x D x ½π = 4 x 15 x 1.57 =
C = 150mm – (4 x D) =150mm – 60mm =
Total length of pipe required =
65 mm *
94.2mm
90 mm
A = 125mm – 4 x D
249.2mm
* = 4 x D = 4 X 15mm
= 60mm
15mm = D
Calculator

14. Bending Copper Pipe video
Please watch the video demonstrating,
‘How to manufacture a 90° bend in 15mm Copper Tube’
Also, there are smartphone apps available to help with this;
iBend Pipe (ios) = £2.49

15. Bending Mark
First, draw a line on the pipe by either measuring 150mm or mark off the drawing.
Then go back from this mark one half of the pipe diameter (7.5mm) and mark the bending mark.
Insert measured end of pipe into the machine and line up bending mark with inside of former using a set square
150mm
Go back ½ pipe diameter = 7.5mm to create bending mark
15mm = D
This is the bending mark that has to be lined up with the former

16. Task 2
Please draw and complete a 90° bend in 22 mm pipe with a 200mm (Y axis) and a 200mm (X axis)

17. Measuring and bending tubes
Task 2
200mm (X axis)
22mm = D *
C = 200mm - 4 x D
200mm
(Y axis) B
= 4xDx½π
A = 200mm – (4 x D) = 88mm – 60mm =
B = 4 x D x ½π = 4 x 22 x 1.57 =
C = 200mm – (4 x D) =88mm – 60mm =
Total length of pipe required = mm
112 mm *
138.2mm
112 mm
A = 200mm – 4 x D
* = 4 x D = 88mm
22mm = D
Calculator

18. Measuring and bending tubes
Task 3 - P5 - Fabricate the following pipe complete with bends and calculate how much pipe is required.
Watch video of ‘How to produce a 60mm offset’
15mm = D
15mm = D
300mm
150mm (Y axis)
60mm
30°
125mm
(Y axis)
90°

19. Unit 204: Common Plumbing Processes
Aims
To manufacture a 90⁰ bend in 15mm copper tube –
{TASK P5 – Copper tube bending 1 [P34 – 6035 practical task manual]}
Objectives
Identify the tools required to complete 90° bend in 15mm copper tube
Complete a drawing of 90° bend in 15mm copper tube to a scale of 1:1
Manufacture a 90° bend in 15mm copper tube to ±3mm and ±3°
Present final 90° bend in 15mm copper tube to be assessed by peers and tutor