You're not alone. This is a common complaint with bending PVC-coated conduit, especially with power benders like the Greenlee 854DX. Here's a breakdown of why it happens and what you can do about it, beyond what Greenlee told you

Why it Happens:
Coating Thickness Variation

Even within the same manufacturer, the PVC coating thickness can vary slightly. Some areas might be thinner or thicker than others. Your Greenlee rep is partly right, inconsistent coating is a factor, but not the whole story.

Pipe Diameter Variation

Slight variations in the pipe's OD (outside diameter) can also cause issues. A pipe that's slightly larger might bind more tightly in the shoe.

Sharp Edges/Burrs on Shoe

Over time, the inside of the shoe can develop small burrs or sharp edges due to wear and tear. These can catch the coating.

Shoe Design & Lubrication

The inherent design of the shoe, particularly the friction between the shoe and the pipe, and the lack of adequate lubrication, can contribute to the problem.

Bending Speed

Bending too quickly can exacerbate the problem, as the pipe has less time to adjust within the shoe.

Solutions and Strategies


Lubrication is KEY! This is the first thing to address: Specific Lubricant

Don't just use anything. Use a lubricant specifically designed for conduit bending. Some good options:

Ideal Industries Yellow 77

A classic for a reason. Apply liberally inside the shoe and along the pipe where it contacts the shoe.

Thomas & Betts Kopr-Shield

Also very good and may provide a bit more slip.

Silicone Spray

Some people have success with silicone spray, but it doesn't always last as long as the others.

Reapply Frequently

Reapply the lubricant after each bend or even during a bend if you hear or feel resistance. Don't be shy with it.

Clean Regularly

Clean the shoe periodically to remove dirt and metal shavings, then reapply the lubricant.2.

Shoe Inspection and Maintenance



Smooth Out Sharp Edges

Carefully inspect the inside of the shoe for burrs or sharp edges. Use a fine file or emery cloth to gently smooth them down. Be careful not to remove too much material.

Check for Wear

Examine the shoe for excessive wear. If it's significantly worn, it may need to be replaced.3.

Bending Technique



Slow and Steady

Bend at a slower, more controlled pace. This gives the pipe more time to adjust and prevents binding.

Gentle Starts

Start the bend slowly and smoothly. Don't "jerk" the bender.

Monitor and Adjust

Watch the pipe closely during the bend. If you see or hear any signs of binding, stop immediately and re-lubricate. You might also need to slightly adjust the pipe's position.4.

Pipe Selection and Preparation



Inspect Pipe

Before bending, inspect the pipe for any obvious defects in the coating, such as scratches, dents, or thin spots. Set aside any pipes with significant coating problems.

Consider a Different Manufacturer

If you consistently have problems with a specific manufacturer's pipe, try switching to a different brand known for better coating quality. It's an expense, but less rework pays for itself.

Warm the Pipe

Warming the pipe slightly can make the coating more pliable, but

BE CAREFUL! Don't overheat it, as this can damage the coating or even the PVC. A heat gun on a very low setting, moved quickly along the area to be bent, might help. Test on a scrap piece first.5. Modifying the Shoe (Proceed with Caution)



Sanding/Polishing

Some electricians carefully sand and polish the inside of the shoe to make it smoother. Use very fine-grit sandpaper (400-grit or higher) and proceed cautiously. The goal is to reduce friction, not to remove significant material. This will void any warranty on the shoe.

Add Teflon Tape or a Sleeve

Some users have added a layer of Teflon tape to the shoe's interior or used a Teflon sleeve. This can reduce friction, but it may wear out quickly and need to be replaced. Again, consider the safety implications.6.

Consider a Different Bending Method



Hydraulic Benders

If you're doing a lot of PVC-coated conduit, consider investing in a hydraulic bender. These tend to be more precise and cause less damage to the coating.

Hand Benders

For smaller bends or short runs, hand benders might be a better option, as you have more control over the bending process.

Important Safety Notes



Eye Protection

Always wear eye protection when bending conduit.

Gloves

Wear gloves to protect your hands.

Proper Grounding

Ensure the bender is properly grounded.

Follow Manufacturer's Instructions

Always follow the manufacturer's instructions for the bender and the conduit.

Don't Overbend

Avoid overbending the conduit, as this can weaken it and damage the coating.

Troubleshooting



If the pipe is still turning

Double-check the shoe size. Is it definitely the correct size for the pipe you are using? Even a slight mismatch can cause binding.

If the coating damage is always in the same spot

Focus your lubrication and inspection efforts on that specific area of the shoe. There's likely a burr or rough spot there.*

Test Bend: Before bending a critical run, always do a test bend on a scrap piece of the same type of conduit to fine-tune your technique and ensure your lubrication is adequate.By addressing these factors and experimenting with different techniques, you should be able to significantly reduce the amount of coating damage and improve the accuracy of your bends. Remember to prioritize lubrication and careful technique! Good luck! Flag for review