Fabricators should not be using a torch when bending, and I have never seen that done at a reputable shop. The rusty corners are the result of spalling of mill scale and the effect of cold work on the bar, not heat.
The 180 degree is a standard hook, and on a #18, it should be about 2'-4.5" out-to-out. Bending a 180 requires the same forces as bending a 90, since the additional bending is performed on an additional length of bar. The hard part is actually bending a hook that big, and even starting a bend in a bar that big requires very large forces.
(And higher grade bar requires substantially more force.)