Rebar Cutting Methods
The Different Ways to Cut Rebar
There are many ways to cut rebar, depending on its size and shape. The most common is with a grinder or a circular saw. However, special tools can make the job much easier. Let’s discuss the different ways to cut rebar and the pros and cons of each method. Keep in mind that safety is always important when working with metal!
The Various Tools That Can Cut Rebar
Reinforced bars, or rebar, are an essential component of concrete construction. They provide added strength and stability to concrete structures, making them ideal for buildings and other large structures. While rebar is typically made from steel, it can also be made from other materials such as aluminum or composite.Based on your project, you might need to cut rebar if:
- The length of the rebar needs to be adjusted to fit the dimensions of the project.
- The ends of the rebar need to be bent or shaped to create a stronger connection with other pieces of rebar or with other materials.
- Damaged or corroded sections of rebar need to be removed.
Choosing a tool to cut rebar depends on the type of material and its application. Common options include:
Production-Level Hand Tools
When it comes to on-site cutting and bending of rebar, nothing beats a tool made specifically for that purpose. Rebar cutters and benders come in all shapes and sizes, but the most crucial factor to consider is the quality of the tool. Let’s start at the beginning with two of the best production-level hand tools for on-site cutting and bending of rebar: the Benner-Nawman #5 5/8" Manual Rebar Cutter
Bender and the Hit Tools #5 5/8" Rebar Cutter Bender.
The Benner-Nawman cutter bender is made from high-strength steel for durability, while the Hit Tools cutter bender features a drop-forged head for added strength.
To use either of these tools, simply place the rebar between the jaws and squeeze the handles until the rebar is cut or bent to the desired length and shape. Both tools are easy to use and require minimal effort to operate.
Keep in mind that these manual cutting tools are designed for smaller jobs and can cut up to #5 rebar. They are more reliable and easier to use than bolt cutters, but since they sit on the ground and require elbow grease as leverage, they can’t be used on installed rebar.
Cordless Combination Rebar Cutters/Benders
These electric combination tools are the next step up from the manual hand tools. The Metabo HPT VB16Y portable rebar cutter/bender is a prime example of this class of tool. With an 8 amp motor and intense power (530 W) that can easily cut, and uniformly bend up to #5 (3/8", 1/2", 5/8") grade 60 rebar at a maximum angle of 180 degrees, these portable tools can easily get the job done. Precision cuts can be made in about 3 seconds, and angle bends are preset and completed in about 5 seconds,and the variable-speed trigger provides manual-like precision and control over the bending speed.
Angle Grinders
Angle grinders with abrasive cut-off discs are an economical option when you only need to do a few cuts, or when working in a tight space. Cordless grinders are ideal when you need to cut rebar that’s already installed. Keep in mind that grinders throw a lot of sparks, which can ignite nearby items or cause burns. Refer to our safety guide for cutting rebar to stay safe.
Circular Saws
Circular saws with metal cutting carbide blades are another option, however, they can be difficult to control, so it's important to have some experience using them before attempting to cut rebar with one. Circular saws can also produce sparks, so stay safe.Bandsaws
Bandsaws feature narrow blades and result in less vibration than say, reciprocating saws. They are ideal for precision cuts but can be bulky. Bandsaws are efficient in cutting metal, but not fast, and would work well for a few cuts, but not the best tool for projects requiring a lot of rebar cutting.
Bolt Cutters
Bolt cutters are commonly used to cut smaller diameter rebar (like #3) and are also good for wire mesh. Longer-handle heavy-duty cutters can cut up to #4, or 1/2" bar, but anything larger would benefit from a tool better suited to the application. Bolt cutters don’t make a neat cut and can leave sharp ends – so be careful.
Cutoff Saws
Cutoff Saws are a very common tool used for cutting rebar on-site. Abrasive blades on 14" saws can cut rebar quickly and are often used to cut full bundles of rebar at one time. This application will create a lot of spark though, so make sure the area is clear. If using a gas cutoff saw, keep any fuel well-away from the cutting area. Fractured abrasive wheels can be extremely dangerous so we highly recommend wearing a face shield.
Hydraulic Cutters
Reciprocating Saw
Reciprocating saws with a good quality carbide, bi-metal or diamond grit blade are designed specifically for cutting through tougher materials like rebar. That said, these are a great option if you have a small number of cuts or are working in a tight space – but are not an efficient option overall. If you do decide to go with a recip saw, don’t forget that high-quality blade.Rebar, Rod, Pipe and Tubing Saw
These saws (like the Benner-Nawman BNCE-20 #6 (20mm) Cutting Edge Saws) are designed specifically for cutting through round metal bars and rods, and can easily cut through rebar. It is compact, lightweight and helps produce cool and clean cuts on your rebar. Most units have an adjustable bar guide to help secure variable material widths and reduce vibration. The BN models have a flush cutting blade guard that reduces blade exposure and sparks. These saws are small, so they’re convenient in hard-to-reach areas – but definitely plan on bringing extra blades to the job.Rebar Cutting Best Practices
When it comes to cutting rebar, there are a few best practices to follow to ensure a safe and accurate cut.- Never cut rebar that is ungraded.
- Never lock the saw or cutter in the ON position.
- Know your tool specifications. Attempting to cut rebar that is tougher, thicker, or thinner than the tool is designed for can result in personal injury and potentially damage your equipment.
- If you use your rebar cutter for unapproved materials, the cut end may expel causing injury (especially on short pieces 12" or less).
- Always wear eye protection when cutting rebar (safety goggles, glasses with side shields or full-face shields).
- Wear heavy-duty gloves and always cut away from your body.
- To avoid electric shock, never handle rebar with damp or wet hands. And never use your cutting tools in the rain or damp environments.
By following these simple best practices, you can ensure a safe and accurate cut every time.
White Cap carries an impressive selection of high-quality rebar cutting tools from brands like Willard, BN Tools, Metabo HPT, Makita, Multiquip, Jet, HIT, and Husqvarna. If you need help deciding which tool is best for your application, please contact us today!