Cutting rebar can be a dangerous and frustrating job. You can use several different tools to cut rebar, but which tool is right for the job, and how do you cut rebar?
The best way to cut rebar depends on the type of rebar you’re cutting, how much you need to cut, the available tools, and the space you are working in. Our guide will help you determine which tool is best for each situation.
Rebar Qualities and Uses
Rebar, which is short for reinforcement bar, is also known as reinforcing steel or reinforcement steel. Reinforced steel bar is used as a building material for its strength and durability.
Rebar is typically used in construction projects such as road work, bridge building, and home construction. Rebar is also referred to as structural steel, where the term “structural” implies a material that has been designed to withstand stress. It is generally made of low carbon structural steel shapes, which are usually provided in metal pipes or coil or pre-punched flat bars.
Rebar comes in different grades that vary in strength, tensile strength, and chemical composition. Some common grades include:
Grade 60 (Yield Strength = 60,000 psi) – Commonly used in the U.S., this grade is designed to yield before it breaks. This means that under stress, rebar will bend rather than break if possible. Some builders prefer Grade 60 for aesthetic reasons because it has a nicer finish than lower grades.
Grade 80 (Yield Strength = 80,000 psi) – This is the most widely used rebar grade in the world. Grade 80 is designed to break rather than bend when placed under a lot of stress before reaching its yield point. The bending that does occur with this type of rebar is usually the result of improper installation.
What tool do you use to cut rebar?
There are several tools that you can use to cut rebar effectively. You may have some of these tools lying around your house, and depending on the type of rebar you’re cutting; it will determine what method is best for you.
The tools used to cut rebar are: Rebar cutter, angle grinder, reciprocating saw, bolt cutters, circular saw, hacksaw, miter saw, torch, chop saw, and cutting wheel.
How to Cut Rebar
This guide will explain how to cut rebar with each method and tool listed above and give you an idea of which method is best for your situation.
1. Rebar Cutter
Yes, there is a specific tool just for cutting rebar. Why is it not universally used? Well, they tend to be a little expensive. However, this is the safest, cleanest, and most effective way to cut the rebar. If you are going to be doing a lot of rebar cutting, it is a very wise investment.
These machines easily cut any grade rebar with no sparks or noise, making an immaculate cut. All with the push of a button. Here’s how to use it.
Step 1: Mark your cut.
Step 2: Place the rebar in the machine and line up the mark to the blade.
Step 3: Press the button. Rebar is cut in less than 3 seconds.
Top Pick for a Hydraulic Rebar Cutter: Anbull 900W Electric Rebar Cutter
This Rebar Cutter cuts up to a 5/8″ rebar with the touch of a button in less than 3 seconds. It has a copper motor for optimum performance. It has an upgraded blade that is sharper and more durable. The handle is ergonomic and made of high-impact PVC. This is built to last. For best performance, be sure to replace the hydraulic oil every 3-4 months.
2. Cut Rebar with Grinder
The angle grinder is a very versatile tool. It can cut a variety of materials just by switching out the discs. An angle grinder gives a clean cut on rebar. However, it can get a little risky. Cutting rebar with a grinder creates a lot of sparks.
You want to make sure you are wearing the correct safety gear and away from anything that would be affected by sparks. Be cautious about kickbacks from the grinder while cutting. Here is a step-by-step on cutting rebar with an angle grinder.
Step 1: Mark your cut on the rebar.
Step 2: Secure the rebar either in a vice or with your other hand.
Step 3: Make sure you have the correct disc in your angle grinder. Please turn on your angle grinder to its highest setting.
Step 4: Bring the grinder straight down on the rebar. Please don’t allow the tool to move side to side; it could potentially snap the disc.
Step 5: Grind the rebar without pushing down with too much force until the rebar starts to fall.
Step 6: Bend the rebar until it breaks the rest of the way.
Top Pick for Angle Grinder: Dewalt Angle Grinder Tool (DWE402W) with an abrasive metal cutting disc.
The 11 amp motor and small size make this the perfect tool for those tough jobs in hard-to-reach places. With the right cutting disc, this tool will easily cut through rebar, even when it’s sticking out of concrete. Safety gear is a must due to the flying sparks.
3. Cutting Rebar with Sawzall
The Sawzall, also known as a reciprocating saw, can be a great tool for cutting rebar. The Sawzall has the power and blade length to cut through larger pieces of rebar in a quick amount of time. You may want to keep your tool on a lower setting to ensure a controlled cut.
It would be best if you had a blade that will cut through metal. Sawzall blades that are used for metal typically have more teeth than those used for wood. Also, make sure you are wearing your safety equipment when using this tool. To get that clean cut on rebar, here’s how it works.
Step 1: Mark where you want the cut to be on the rebar.
Step 2: Secure the rebar in a vice.
Step 3: Start your Sawzall up and bring it down as flat as possible on the rebar. Don’t push down too much; let the blade do the work slowly until you are through metal.
Top Pick for Reciprocating Saw: Dewalt 12-Amp Reciprocating Saw DWE305 with the Diablo Demon Demo Blades
The Dewalt DWE305 Saw has a powerful 12-amp motor that can tackle most heavy-duty projects. There is a 4 position blade clamp and a variable speed trigger. When used with the Diablo Demon Demo Blades, you can easily cut the rebar. Sparks fly while you cut, so safety gear is a must.
4. You Can Cut Rebar with Bolt Cutters
Bolt Cutters are designed to cut through bolts and chains, so it makes sense that they should cut through rebar as well. Bolt cutters don’t give as clean a cut as some of the other tools, but it gets the job done. If you have many pieces to cut, your hands may be pretty sore, depending on the strength of your bolt cutters. When cutting rebar with bolt cutters, the process is pretty straightforward.
Step 1: Mark your cut on the rebar.
Step 2: Place the blade of the bolt cutter down on one side of where you marked and squeeze together.
Step 3: Repeat on the other side if necessary.
Top Pick for Bolt Cutter: KSEIBI 24 inch Bolt Lock Cutter Hand Jaws
These bolt cutters have extra long handles for extra comfort during those tough cuts. The compound cutting action of the three-stage lever means you don’t have to give a lot of effort for more force. They have an adjustable jaw, so you get more precise cuts.
5. How to Cut Rebar with a Circular Saw
A circular saw with the correct blade will easily cut the rebar. There are a couple of different blades that will work. You can get a blade rated to cut ferrous metal, or you can go with the diamond blade, which is more effective and lasts longer. Sparks and metal shavings will be flying; make sure you are wearing all your safety gear, and bystanders are a safe distance away.
Step 1: Mark your cut.
Step 2: Secure rebar in a vice.
Step 3: Turn on your saw and bring your blade down on the cut line.
Top Pick for Circular Saw: Makita 5007Mg 7-1/4 inch Circular Saw
The Makita Circular Saw features durable magnesium components and a powerful 15 amp motor. This lightweight saw is easy to use and made to last. From framing to masonry to metal cutting, this saw can do it all. Pair it with a diamond blade metal cutting blade, and you can easily cut the rebar.
6. Cut Rebar with a Hacksaw
A hacksaw will work to cut the rebar. It is quite a labor-intensive job, so it is not recommended for large quantities of rebar. However, if you have a hacksaw handy and need to cut a couple of pieces of rebar, it can get the job done. Wear your safety gear and be patient to get a clean cut.
Step 1: Measure and mark your cut on the rebar.
Step 2: Secure the rebar in a vice or with clamps on your worktable.
Step 3: Position the hacksaw on the mark and start making small, short-cutting movements back and forth until it creates a groove.
Step 4: Once a groove is made, start lengthening your cuts using almost the whole length of the saw. Use steady long movements until it cuts through.
7. Cut Rebar with a Miter Saw
Like the circular saw, when fitted with the correct blade, you can use a miter saw to cut rebar. Line up the mark on the rebar under the blade, turn your saw on, and cut down. This is a fast way to cut rebar, but it is not very portable.
8. Cutting Rebar by Torching
Rebar can be cut with heat by using an Acetylene and Oxygen Cutting Welding Torch. It is not recommended because it does not create an immaculate cut. You also need to know how to use the torch as it can be quite dangerous. Welders or metalworkers that have the torch readily available typically would use this application if they needed to cut a few pieces of rebar.
Tips for Cutting Metal Safely
- wear safety glasses and ear protection
- allow cut metal to cool before touching it
- secure metal in vice or with clamps before cutting
- make sure workplace is clear of combustible items
- be aware of flying sparks and debris
- observe safety precautions on tools
- wear protective clothing and gloves
FAQs about Cutting Rebar
1. Is rebar easy to cut?
Rebar is made of high carbon steel, which can make it difficult to cut. It requires many different tools such as a grinder, torch, or even saws depending on the type of rebar you are cutting and how clean of a cut you need. When you use the right tool for the job, you can cut rebar easily.
2. The fastest way to cut rebar?
The fastest way to cut rebar is using a hydraulic rebar cutter. These machines can cut any rebar in less than 3 seconds, making them ideal when you need to cut many rebars. Another fast way to cut rebar is using a torch, but it is also the most dangerous and does not give a clean cut. Depending on how much you need to cut and what type of tools you have available, will determine which method would be the best choice for you.
3. What is the best way to cut rebar?
Everyone’s situation differs. If you only have a few pieces to cut, using a hacksaw and vise is fine. However, if you need to cut many pieces of rebar quickly and with the cleanest possible edge, use a hydraulic cutter.
The most versatile way is to use a circular saw, chop saw, or miter saw with a good diamond blade made for metal. These are the most widely used tools because if you don’t have a ton of rebar to cut, you might not want to buy a tool specifically for rebar. No matter what tools you use to cut rebar, be sure to wear all your safety equipment; these tools produce many sparks and metal debris that can be dangerous.
4. Can you cut rebar with a hacksaw?
Yes, you can use a hacksaw to cut the rebar. They are inexpensive, and you will need a vice or table to secure the metal while sawing, but if you only need to cut one piece of rebar, it is your best bet. Remember, when using a hacksaw, wear safety glasses and gloves. Start with short cuts, and once a groove is created, make longer cuts.
5. Can you cut rebar with a Dremel?
A Dremel can cut rebar using a cut-off wheel, but you may go through a lot of wheels before the job is done. Dremels are made for more light-duty work. An angle grinder would be better for cutting rebar than a Dremel. They have more power and better discs for the job.
Conclusion
In this article, we’ve given you a variety of options to cut the rebar. You can decide which tool is best for your situation and budget. When deciding on the right tool to buy or use, be sure to take into account how much rebar you need to cut. Cutting a lot of rebar by hand using a hacksaw can be very difficult.
Remember that most tools listed produce sparks when cutting metal, so safety should always be your top priority. Don’t forget to wear all appropriate protective gear before starting any project involving rebar.
