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Different Ways To Cut Rebar

Different Ways To Cut Rebar

Rebar is made of 95% recycled materials. Reusing steel to create rebar significantly reduces expenses. It's good for the environment as well. Rebar can be produced up to sixty feet in length. For various buildings and applications, different lengths of steel are required. The rebar usually needs trimming.

Rebar can be cut in a variety of ways based on its size and shape. Using a circular saw or grinder is the most typical. Special tools, however, can significantly simplify the task. Let's talk about the advantages and disadvantages of various rebar-cutting techniques. Remember that safety comes first when handling metal!


Rebars, or reinforced bars, are a crucial part of concrete construction. They are perfect for buildings and other large constructions because they provide concrete structures with more strength and stability. Although steel is the most common material used to make rebar, it can also be formed from composite or aluminum.

Depending on your project, cutting rebar may be necessary if:

  • It is necessary to modify the rebar's length to match the project's measurements.
  • To establish a more robust connection with additional rebar or with other materials, the ends of the rebar must be bent or curved.
  • Rebar portions that are rusted or damaged must be removed.

Depending on the material and its intended use, a specific tool must be selected to cut rebar. Typical choices consist of:


Nothing beats a tool designed expressly for the task of cutting and bending rebar on the spot. Although rebar cutters and benders come in a variety of sizes and shapes, the quality of the instrument is the most crucial consideration.

Let's start at the beginning with the Benner-Nawman 5/8" Manual Rebar Cutter Bender and the Hit Tools 5/8" Rebar Cutter Bender, two of the most excellent production-level hand tools for on-site rebar cutting and bending.

While the Hit Tools cutter bender has a drop-forged head for extra strength, the Benner-Nawman cutter bender is composed of high-strength steel for durability.

The rebar may be cut or bent to the required length and shape by simply placing it between the jaws of either tool and applying pressure to the handles until the desired result is achieved. Both of these instruments are simple to use and take little effort to use.

Remember that these hand-cutting instruments are intended for simple tasks. They are more straightforward to operate and more dependable than bolt cutters, but they cannot be used on installed rebar since they rest on the ground and need elbow grease for leverage.


The next improvement over manual hand tools is these electric combo tools. These portable tools are pretty powerful (530 W) and include an 8 amp motor that can readily cut and uniformly bend up to #5 (3/8", 1/2", and 5/8") grade 60 rebar at a maximum angle of 180 degrees. A variable-speed trigger allows for manual-like precision and control over the bending speed. Precision cuts can be done in approximately 3 seconds, and angle bends can be preset and completed in about 5 seconds.


When working in confined spaces or needing to make minor cuts, angle grinders equipped with abrasive cutoff discs are a cost-effective choice. When cutting pre-installed rebar, cordless grinders are the best tool. Remember that grinders emit a lot of sparks, which have the potential to burn people or ignite surrounding objects. To ensure your safety when cutting rebar, consult our safety advice.


Another option is to use a circular saw with metal-cutting carbide blades, but these saws can be tricky to operate, so practice using them before trying to cut rebar. Be careful since circular saws blades can also produce sparks.


Compared to reciprocating saws, for example, bandsaws produce less vibration because of their narrow blades. Although they can be heavy, they are perfect for precise cuts. Bolt cutters


The power of this technology should not be taken lightly. This tool's primary uses are the removal of chains and padlocks. However, they can also easily snap rebar. The bolt cutter has scissors-like blades that are razor sharp, and it can cut through metal with a force of more than 4,000 lb. It is a portable but effective instrument for cutting rebar.


Cutoff saws are a frequently utilized instrument for on-site rebar cutting. Rebar can be swiftly cut with 14" saws' abrasive blades, which are commonly used to cut entire bundles of rebar at once. However, a lot of sparks will be produced by this application, so make sure the space is free. Fuel should be kept well away from the cutting area when utilizing a gas cutoff saw. Since broken abrasive wheels can be quite harmful, we strongly advise donning a face cover.


Even the thickest rebar may be swiftly cut through with hydraulic cutters thanks to hydraulic pressure. These are a more expensive choice, but they are a "must-have" and readily pay for themselves if you work on larger contracts where output is an issue. Strong battery alternatives are also available for cordless hydraulic rebar cutters. They provide clean, spark-free cuts in a matter of seconds and are incredibly simple to use.


Reciprocating saws are made especially for cutting through more complex materials like rebar when they have a high-quality carbide, bi-metal, or diamond grit blade. These are an excellent choice if you have a few cuts or are working in a small area, but they could be more efficient alternatives overall. In the event that you choose to use a reciprocating saw, remember to bring along some premium recip blades.


These saws are made especially for cutting through round metal bars and rods, and they can readily cut through rebar. One example of such a saw is the Benner-Nawman BNCE-20 #6 (20mm) Cutting Edge Saws. It helps create neat cuts on your rebar and is lightweight and portable. To aid in securing varying material widths and lessen vibration, the majority of units incorporate an adjustable bar guide. A flush-cutting blade guard on the BN series reduces spark exposure and blade exposure. Because these saws are compact, they're helpful in places that are difficult to reach, but make sure to pack extra blades for the task.


There are a few best practices to adhere to when cutting rebar to guarantee a precise and safe cut.

  • Never cut ungraded reinforced bars.
  • Turn the saw or cutter on by locking it in place.
  • Understand the specifications of your tool. If you try to cut rebar that is thicker, thinner, or more challenging than what the tool is made for, you run the risk of hurting yourself or your equipment.
  • The cut end of your rebar cutter may eject and cause harm if you use it on unsuitable materials (particularly on short portions of 12" or less).
  • When cutting rebar, always wear eye protection (full-face shields, safety goggles, or glasses with side shields).
  • Make sure you always cut away from your body and wear heavy-duty gloves.
  • Rebar should never be handled with moist or damp hands to prevent electric shock. Additionally, avoid using your cutting instruments in wet or rainy conditions.


Several strategies have been discussed. Some are less expensive, and some are more effective. While some are handled, others are swift. No matter how, safety must always come first. This clearly shows that there are better techniques to cut rebar.

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