15 Ways to Cut Rebar: Which is The Best For You | machineSL.com

Rebar is mostly made up of 95% recycled material. Recycling steel to make rebar saves a lot of costs. It is also beneficial for the environment.

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When manufactured, rebar can have lengths more than 60 feet. Different structures and purposes require different lengths of steel. So most of the time rebar requires cutting. If you’ve never done this task before then this guide will make you confident in cutting rebar.

There are different ways to cut rebar, some of which we will mention below:

Using a hacksaw to cut rebar is the most basic, cheapest, and labor-intensive method. The user requires a lot of patience and arm-strength to cut reinforcement steel.

To use a hacksaw, first, you have to measure the rebar and mark the points you want to cut. Then you have to clamp the rebar for safety.

After that, make slow cuts on the marked points until you form a groove on it.

Finally, start making long steady cuts until the rebar is cutted off.

This option should always be your last resort. This is because the blades dull out too soon.

You can find angle grinders in any place where power tools are sold. You can buy them in different sizes but the most common ones used for cutting rebar are the 4 in. and 4.5 in. grinders.

People prefer them because of their ability to give quick and rough cuts. You can use these to cut rebar, angle irons, rusted bolts, and welding wire fences.

The important thing about angle grinders is to be cautious of them. These devices spin at a rate of to rpm and can be dangerous.

A word of advice is to avoid using thick wheels as the extra friction will make the process slower.

Circular saws are the first priority for most people. These are popular because they can cut through anything very easily.

It cuts metal like a hot knife through butter. The most important point to remember is to use the diamond blade for the circular saw.

You use diamond blades for quality cuts and to avoid problems that arise from using dull blades.

It uses electricity to operate. It also has a long extension cord.

The power of this device should not be underestimated.

This device is mostly used to remove padlocks and chains. But they are also efficient in snapping rebar.

The bolt cutter has sharp blades like scissors and has a metal cutting force of more than lb.

It is a handy yet powerful tool to keep with you for chopping rebar.

The jigsaw is a powerful handheld tool for cutting rebar.

You press the trigger in the handle to operate it. It is suitable for cutting metal from 10mm to 30mm.

The jigsaw contains a metal base called the shoe. Always place the top of the shoe at the surface of the object you want to cut.

When using a jigsaw, hold it steady and use gentle pressure. Take breaks to oil the metal to avoid damaging it.

If the blade gives a feeling that it will break, stop it immediately and move it away. Safety should be of top priority.

You can also cut rebar using a miter saw.

It can cut the metal straight at a 90-degree angle or even at other angles. You will find the device more suitable to use for cutting timber.

It has some common features with other power saws like chop saw or circular saw.

The purpose of cutting torch is to cut metal with heat.

The torch will heat the part of the metal where you point it at and make it malleable or soft. After you heat it, use a stick or pipe or bend it and snap it.

Even though you can cut fast, if you are not an expert then the result may be irregular. It is important to keep in mind that the cutting torch can give the rebar a rounded or uneven cut section.

You should always avoid the use of plasma torches or oxyacetylene torches for large jobs. This is because of the way they operate.

A drawback of using plasma or oxyacetylene is the generation of slag or wastage around the cut. Plasma also takes up a lot of time and electricity, making it costly.

A rotary hammer is just like a drill machine. It has its advantages in the cutting of the reinforcement bar.

It is a precise, fast, and less labor-intensive method.

To cut rebar, you have to use the rotary hammer in the rotation mode instead of the hammer mode.

Like any other handheld, it also has a long extension cord.

A chop saw is a very important tool when discussing rebar cutting. It is similar to a miter saw but differs in its blade. It uses a type of large carbide blade.

You have to adjust the speed of the device to your desired setting and cut through the reinforcement bar.

It is a one-time investment of about $200, but this is one of the most ideal options for cutting rebar in a large quantity. This is because of its very big size.

The resulting cuts formed by the chop saw are very clean and smooth. This is more accurate than the angled grinder and the circular saw.

Its only drawback is that it makes a very loud noise and is not easily portable.

It is a very preferred method and is just like the simple bolt cutter. It is very cheap, portable, lightweight, and does not make any sound.

The device requires pumping to build up pressure. It is then used to cut through the metal rebar very smoothly.

No extension cord, electricity, or batteries are required in this method. It is best suited for small jobs.

Rebar can also be cut using a reciprocating saw. It is also known as teeth saw.

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The method is to set the device in the straight mode instead of the oscillating mode. To avoid damaging the blade, set the speed to slow.

For thin metal, choose a blade of 20 to 25 TPI (teeth per inch). 10 to 17 TPI for medium thick metal and around 7 to 9 TPI for thick metal.

To extend the life of a blade, buy a carbide tooth blade. Using a blade with a hacktooth pattern will prove to give the best results.

Saving the best method for last. Rebarsmachine’s electric bar cutter is the most efficient way of cutting rebar.

It is also the easiest way. It is a 450-600 Kg machine with wheels, making it portable. Professional companies use this machine to cut rebar at the site cleanly and quickly.

There are many variations of the machine and each machine has a separate limit of rebar it can cut.

The machine consists of a cutting clutch that allows the user to control the process. Support brackets are provided in the machine to support the cutting process safely. The machine has a lifting ring that allows you to carry it anywhere you like. The machine operates on oil and has an oil hole on it. It uses a three-phase power source.

This is one of the safest and fruitful investment for a company.

It is better than buying cheap tools for rusty works. Different variations are GQ40A, GQ40B, GQ45A, GQ50A, etc.

We have mentioned various methods above.

Some give better results, while some are cheap. Some are handheld while some are fast. No matter what the method, safety should always be of top priority.

From this, you can clearly conclude that a single perfect method to cut the rebar does not exist.

There are many factors that you should consider when choosing a method. Some of these factors are:

• Time
• The quantity of rebar
• Size of rebar
• Quality of the result
• Budget
• The expertise of manpower
• Accessibility of the tools

The first step is to encase the steel bar inside two pieces of metal piping.

Next, thread the steel bar through both pipe pieces and let them intersect at the point where you want to bend.

On one end of the metal piping, weigh the piping down and show the portion of the rebar that you want to bend. Use leverage to raise the longer piece of the pipe from the floor.

To bend the solid rebar, you will need an appropriate amount of manpower/force. Although the leverage you will get by using a long piece of pipe will help in getting the process move along.

Now that you have allowed the bar to bend, you will need to measure the angle. Having a carpenter’s square will help you in measuring the angle of bending.

Angle control is one of the most important steps of the process. Different uses of rebar require different angles. If a third person can hold the carpenter’s square while bending then you can easily obtain the right angle.

This method of rebar bending has its limits.

• You cannot bend bars of very large diameter.
• You cannot bend rebars in a high capacity either.
• This method damages the rebars at the point of bending as well.

These studs are there to hold the rebar in position. The bar is around 34 inches long and weighs around 4 pounds. It uses the principle of increasing the torque to bend the reinforcement bar. People prefer it because of its small size and portability.

The handle of the hickey bar is designed as such to give considerable pressure to bend the rebar. Its use is such that one bar is not enough to bend the bar, you always need two of these.

If one of the studs breaks, you can always fix it using a torch and a grinder. You can always shorten the length of the bar using a hacksaw.

The process starts with placing the rebar straight on the ground.

Hold it using one of the hickey bars. Hold it in such a way that the rebar passes through two of the studs. Remember to use two hickey bars to bend the rebar. Now use the second hickey bar and again hold the bar using it.

The distance between the two holdings is where the bar will bend. So, the shorter the distance, the more accurate will be the point of the bend. Now, apply force to the second hickey bar. This will create torque and will make bending the bar very easy.

Angle control is very important. It would be helpful if a second person could use a measuring square to check the angle of bend during the process.

While it has its advantages, it also has some limitations.

• You cannot use it for Grade 60 and above.
• The maximum diameter of the bar also depends upon the distance between the studs.
• Usually, it cannot bend bars of more than 5/8 inches.

It uses the same principles as the hickey bar for rebar bending. It has a long lever and a CAM mechanism to generate maximum torque. The device weighs around 12 to 15kg. They are portable and economic. The price of this device ranges from $200 to $500 depending upon the variations.

The first step is to select the correct setting for the rebar you are bending. Simply pull the CAM towards you and rotate to the preferred setting. The numbers on the dials mean the diameter of the bar you want to bend in millimeters.

Once you have adjusted the settings, we move on to the next step. Put the rebar in place and apply force on the lever until the bar is bent.

Most tools only bend the bar up to 90-degree. If you want to make a stirrup then you have to repeat the steps four times for each corner.

If the force is not enough to bend the bar then do no increase the lever size or apply more force. It will only damage the machine. This only means that the rebar size is too much for the machine.

There are a lot of variations of this device. Every variation has its limits and drawbacks. Most of its variations can only cut bars up to 5/8 inches. Some of its variations only bend bars up to 90-degree.

It is a slow machine and can only bend one bar at a time. Most of the variations cannot bend bars of grade 60 and above.

You should always keep this device away from dirt, mud, water and dust. If you expose the machine to these, it will damage its internal mechanism.

Before buying, you have to keep in mind some factors. These are bender capabilities, power requirements, cost, and time taken by the machine.

This type of machine bends rebars easily and without damaging its strength. They are easy to operate and transport.

It works on both electricity and hydraulic power. Different variations can bend different sizes and grades of rebar. This device even allows you to bend rebars coming out of walls and columns. A lot of its variations come in a mixer of rebar cutter and bender. This makes a lot of tasks very easy.

The process does not have a lot of steps. You place the rebar in the grip and turn the machine on. The hydraulic press will bend the bar in 4 seconds. The machine can bend up to 180-degree. It can bend up to bars of 1-inch size. These may be a little expensive but are essential where you need accuracy and speed.

It is a large-sized machine. The machine is multi-purpose and you can use it for rebars of all shapes, sizes and types. It has a big working platform. You can even change the pillars or studs used to bend bars. Different sizes and types of bars require different pillars.

The machine also has very simple indicator lights. It has a red reverse indicator light and a green forward indicator light. It works on pulleys and gears that allow it to bend strong bars. And it has different index pins to bend rebars at different angles.

It has a lot of safety features. An emergency stop button in case something dangerous happens. The machine comes with a footswitch that lets you control the process as you want.

How does this machine work? First, set up all the pillars according to the rebars you want to bend. Then set up the indexing pieces according to the angle you desire. Next, place the bar between the solid bending disc and the square stick.

Press the footswitch and the bar will bend in less than 3 seconds. You can create an entire stirrup without taking the rebar out once.

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