How To Cut Rebar? 15 Ways You Need To Know

Cut Rebar

Rebar is frequently used on construction sites as concrete reinforcement. Standard lengths of rebar are brought to the job site; they must then be cut and bent to size.

Rebar can be made in lengths up to 60 feet when it is manufactured. Steel must be cut to different lengths for various structures and uses. Accordingly, cutting is usually necessary for rebar.

How to cut rebar? Using specialized bar cutters is the best method for cutting rebar. The metal-cutting chop saw is typically the next best choice for most people if they are unable to spend money on specialized equipment.

For this task, a wide range of instruments are frequently used; some are riskier and less prudent than others. Here are a few of the most popular ones.

Purpose Of Rebar

Concrete products can be reinforced with rebar alone or in conjunction with steel mesh wire. It is frequently produced locally using discarded automobiles and appliances. Rebar is primarily (97%) made of recycled materials. You will need to make adjustments when working with steel rebars because they are typically cut into lengths up to 60 feet long.

  • ​Makes sure that the tension and compression in the concrete remain equal
  • ​Is environmentally friendly

Before You Begin Cutting

Before you begin cutting, there are a few setup and safety precautions to follow.

  1. Rebar should first be measured before being cut. Typically, it is offered for sale in lengths of around 20 feet. As long pieces of rebar are probably what you’ll be working with, it’s critical to take precise measurements before cutting.
    You should include that in your measurements if you need to bend it in any direction. Each of your cuts should be measured with a tape measure and marked with chalk. This way, you will know where to begin your cut
  2. When cutting steel, take the necessary safety precautions. Rebar can be very heavy, and the ends are pointed. It will produce sparks as you work with it, and metal shavings will fly through the air as you cut a metal surface with a metal blade. Wear the appropriate safety gear, exercise caution, and Think about donning a mask, some goggles, and gloves in addition to a long sleeve shirt, pants, and work boots.
  3. Make sure your workspace has enough space to accommodate rebar. They can range in length from 8 to 60 feet. Being an open area is ideal for working because there are no obstacles in the way. Make sure your workspace is free of any flammable materials, such as your fire pit necessities or any cooking supplies, as rebars produce sparks when you work with them.

How To Cut Rebar?


The simplest, least expensive, and most time-consuming technique for cutting rebar is to use a hacksaw. To cut reinforcement steel, the user needs a lot of patience and arm strength.

To use a hacksaw, you must first measure the rebar and mark the desired cutting points. For safety, you must next clamp the rebar.

After that, slowly cut along the marked points to create a groove.

Once the rebar has been severed, start making long, steady cuts.

Always make this choice your last resort. This is due to premature blade dulling.

Angle Grinder

Angle grinders are available everywhere that sell power tools. They come in various sizes, but the 4 in. ones are the ones that are most frequently used to cut rebar. and 4.5 in. grinders.

They are more favored because they can make quick, rough cuts. Rebar, angle irons, rusted bolts, and welding wire fences can all be cut with these.

The most important thing to remember about angle grinders is to avoid them. These potentially dangerous machines spin between 10,000 and 11,000 rpm.

A piece of advice is to steer clear of using thick wheels because the added friction will slow down the process.

Angle Grinder

Reciprocating Saw

A reciprocating saw may also be used to cut rebar. Teeth saw is another name for it.

The process involves switching the device to straight mode from oscillating mode. Set the speed to a slow rate to prevent blade damage.

Choosing a blade with 20 to 25 TPI (teeth per inch) is appropriate for thin metal. 10 to 17 TPI for metal that is medium in thickness and 7 to 9 TPI or more for thick metal.

Buy a blade with carbide teeth if you want to prolong the life of it. The best outcomes will likely be obtained when using a blade with a back tooth pattern.

Circular Saw

Most people place a high priority on circular saws. These are widely used because they easily cut through any material.

It slices through metal like hot butter through a knife. The most crucial thing to keep in mind is to always use a diamond blade with a circular saw.

In order to get good cuts and stay away from issues brought on by using dull blades, you use diamond blades.

It is powered by electricity. It has a lengthy extension cord as well.

Bolt Cutter

It’s important not to undervalue this device’s power.

Most commonly, chains and padlocks are cut off with this tool. However, they are also proficient at snapping rebar.

With more than 4000 lb of metal-cutting force, the bolt cutter has razor-sharp blades similar to those of scissors.

When you need to cut rebar, it is a useful but potent tool to carry around.


Heat is used by a cutting torch to cut metal.

When you point the torch at a piece of metal, it will be heated and become soft or malleable. After heating it, bend and snap it with a stick or pipe.

If you are not an expert, even though you can cut quickly, the outcome might be irregular. The cutting torch may give the rebar a rounded or uneven cut section, which is something to keep in mind.

For big jobs, you should never use oxyacetylene or plasma torches. Due to the way they conduct business, this.

The production of slag or waste around the cut is a disadvantage of using plasma or oxyacetylene. Furthermore expensive and requiring a lot of time and electricity is plasma.

Pincer Pliers

These are more frequently used for rebar tying than rebar cutting.

Since you use them like a pair of scissors, they lack the power needed to cut a 4 mm rebar. Nevertheless, they are capable of cutting metal wires.

Cutting Wheel

With the exception of the table, the cutting wheel method is very similar to the table saw method.

Cutting reinforcement bars is a breeze with this steel cutting wheel.

Using a clamp to hold the bar, make slow cuts. Before using this device, you must ensure that your surroundings are secure.

Rotary Hammer

Similar to a drill, a rotary hammer is a tool. The cutting of the reinforcement bar has benefits.

It is a precise, quick, and less time-consuming method.

Use the rotary hammer in rotation mode as opposed to hammer mode to cut rebar.

It has a long extension cord just like any other handheld device.


The jigsaw is a potent hand tool for cutting rebar.

To operate it, you squeeze the trigger located in the handle. Metal between 10mm and 30mm can be cut with it.

A metal base known as the shoe is included with the jigsaw puzzle. To cut an object, always position the top of the shoe against the surface.

When using a jigsaw, keep it steady and apply light pressure. To prevent damaging the metal, oil it during breaks.

Immediately stop and move the blade away if it appears as though it might break. Safety should come first.

Miter Saw

Rebar can also be cut using a miter saw.

A 90-degree angle or even other angles can be used to cut the metal straight. You’ll discover that the tool works better for cutting wood.

It shares some characteristics with other power saws, such as the chop saw and circular saw.

Chop Saw

When discussing the cutting of rebar, a chop saw is a crucial tool. It resembles a miter saw but has a different blade. It utilizes a specific kind of large carbide blade.

To cut through the reinforcement bar, you must set the device’s speed to the desired setting.

One of the best options for cutting large quantities of rebar, it requires a one-time investment of about $200. This is a result of its enormous size.

The chop saw produces incredibly smooth and clean cuts. The circular saw and the angled grinder are less precise than this.

The fact that it is difficult to transport and makes a lot of noise is its only downside.

Hydraulic Bolt Cutter

It is very popular and resembles a basic bolt cutter. It makes no noise, is very affordable, and is portable and lightweight.

Pressure must be generated by pumping the device. The metal rebar is then cut very smoothly with it.

Using this technique doesn’t require an extension cord, electricity, or batteries. Smaller jobs are best suited for it.

Portable Rebar Cutter

The use of the portable rebar cutter is one of the newest innovations on the market.

It is a hand-held, mobile device that utilizes both hydraulics and electricity. It has a 5-second cut time for up to #8 bars of Grade-60. For added security, it has a lock trigger switch.

The absence of flame or spark production is the best feature of this machine.

Rebar Cutting Machine

Leaving the best approach until last. Rebarsmachine’s electric bar cutter is the most efficient way of cutting rebar.

Additionally, it is the simplest method. It weighs between 450 and 600 kg and has wheels, making it portable. This machine is used by expert businesses to quickly and cleanly cut rebar on the job site.

Each machine has a unique limit on the amount of rebar it can cut, and there are numerous variations of the machine.

A cutting clutch on the machine enables the user to regulate the action. The machine has support brackets to ensure the cutting process is carried out safely. The device has a lifting ring that enables you to move it wherever you please. The device has an oil hole on it and runs on oil. It makes use of a three-phase power supply.

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