Aluminum vs iron conduit benders
By Andrew ·
Quick answer
An aluminum hand bender is lighter to carry; an iron or ductile iron one is heavier and tougher. The bends are the same. Greenlee’s aluminum and iron heads share every centerline radius and deduct, 5", 6", 8" and 11" for 1/2" to 1-1/4" EMT, so the marks and the gain don’t change with the metal. Choose on weight, durability and the sizes each brand makes.
Shoe by shoe
| Shoe | Greenlee aluminum hand bender: radius | Greenlee aluminum hand bender: deduct | Greenlee iron hand bender: radius | Greenlee iron hand bender: deduct |
|---|---|---|---|---|
| 1/2" EMT | 4 3/16" | 5" | 4 3/16" | 5" |
| 3/4" EMT | 5 1/8" | 6" | 5 1/8" | 6" |
| 1" EMT | 6 1/2" | 8" | 6 1/2" | 8" |
| 1-1/4" EMT | 9 5/8" | 11" | 9 5/8" | 11" |
| 1/2" rigid (RMC) | 5 1/8" | 6" | 5 1/8" | 6" |
| 3/4" rigid (RMC) | 6 1/2" | 8" | 6 1/2" | 8" |
| 1" rigid (RMC) | 9 5/8" | 11" | 9 5/8" | 11" |
| 1/2" IMC | 5 1/8" | 6" | 5 1/8" | 6" |
| 3/4" IMC | 6 1/2" | 8" | 6 1/2" | 8" |
| 1" IMC | 9 5/8" | 11" | 9 5/8" | 11" |
Same marks in either metal
Greenlee lists its aluminum heads (840A to 843A) and iron heads (840F to 843F, or FH with a handle) in one specifications table, with the same numbers for both: a 4 3/16" radius and 5" deduct for 1/2" EMT, up to 9 5/8" and 11" for 1-1/4". Rigid and IMC ride one head up in either metal, so 1/2" rigid bends in the 3/4" EMT head and deducts 6".
The other brands in BendMate that come in both metals follow suit: Klein’s, IDEAL’s and Milwaukee’s aluminum and iron heads for the same size carry the same deduct. The shape of the shoe sets the marks, not what it is cast from.
What the metal does change
| Aluminum | Iron or ductile iron | |
|---|---|---|
| Weight | Lighter to carry up a ladder and around a job | Heavier |
| Toughness | Softer metal that a hard drop can nick or bend | Tougher, and stands up better to knocks |
| Marks and numbers | Same as iron, size for size | Same as aluminum, size for size |
| Sizes in BendMate | Greenlee to 1-1/4" EMT; Milwaukee and Gardner Bender to 1"; Klein, IDEAL and Southwire to 3/4" | Greenlee, Klein and IDEAL to 1-1/4" EMT; Milwaukee to 1" |
Weight matters most on the small heads you carry all day. Toughness matters more on the big heads and on rigid, which take more force, and some brands make those sizes in iron only: Klein’s and IDEAL’s 1" and 1-1/4" heads are iron.
Which to buy
- Mostly 1/2" and 3/4" EMT, carried from floor to floor: aluminum saves weight, and the marks are the same.
- Rigid and IMC, or 1" and 1-1/4" EMT: iron is tougher, and for some brands it is the only choice.
- A bender that rides loose in a truck bed or gang box: iron takes the knocks better.
- A crew sharing benders: within one brand, mixing metals doesn’t change the marks.
In BendMate
Both Greenlee heads are built in, and hand benders are part of the free version: offsets, 3- and 4-point saddles, 90s and kicks, with no signup. Because their numbers are identical, the aluminum and iron entries give the same marks; pick the one you own so the name matches your tool. If your head bends long or short, edit its deduct in Bender Specs and every mark follows.
Get the marks for your bender
BendMate works this out from your bender’s radius and deduct, flags a bend that won’t work, and shows you every mark.
Free for offsets, saddles, 90s and kicks with a hand bender. No signup.
Common questions
Is an aluminum or iron conduit bender better?
Neither bends better: on Greenlee’s heads the radius and deduct are identical. Aluminum is lighter to carry, and iron is heavier and stands up better to rough use.
Do aluminum and iron benders have different take-up?
Not for the same brand and size in BendMate’s library. Greenlee’s aluminum and iron heads both deduct 5", 6", 8" and 11" for 1/2" to 1-1/4" EMT, and Klein, IDEAL and Milwaukee match across metals too.
Can an aluminum bender bend rigid conduit?
Yes, the small sizes. Greenlee’s aluminum 3/4" EMT head also takes 1/2" rigid and IMC, with a 6" deduct, and its larger heads go up to 1" rigid.
BendMate is independent and not affiliated with QuickBend, any bender manufacturer or their makers. Product names are used only to identify what people search for.