How this calculation works

Stubs and take-up

A bender does not turn the pipe at a point. It turns it over an arc, and that arc consumes length. Take-up is how much. Subtract it from the stub height you want and that is where the mark goes.

90 degree stub
mark = stub height − take-up

Common EMT take-up: 5" on 1/2", 6" on 3/4", 8" on 1", 11" on 1-1/4". Rigid and IMC take more because the bend radius is larger.

Offsets and multipliers

An offset is two equal bends in opposite directions. The distance between them is the obstacle height times a multiplier that comes from the angle.

Offset multipliers
10° → 6.0  ·  22.5° → 2.6  ·  30° → 2.0  ·  45° → 1.4  ·  60° → 1.2

The multiplier is the cosecant of the angle. At 30 degrees the cosecant is exactly 2, which is why 30 is the angle everybody defaults to — the math is doable on a ladder.

Shrink, the thing that gets forgotten

Bending an offset pulls the end of the pipe back toward you. If you cut to your original measurement and then bend, the pipe comes up short. Shrink per inch of rise: about 1/16" at 10 degrees, 3/16" at 22.5, 1/4" at 30, 3/8" at 45, and 1/2" at 60.

A 6 inch rise at 30 degrees shrinks about 1-1/2 inches. On a run to a fixed connection, that is the difference between landing in the box and coming up short of it.

Three-point saddles

A saddle crosses an obstacle and comes back to the original line. The center bend is twice each outer bend — a 45 degree center with two 22.5 degree outers is the standard. Mark the center of the obstacle, then measure out to each side by the obstacle height times 2.5 for a 45 degree center.

Above all this sits one hard limit: 360 degrees of bend between pull points. Four 90s, or any combination that adds to a full circle, and you need a box.