Ever wondered how to cut rebar but you weren’t sure where to start? You’re certainly not alone!
In this guide, I’ll use my 20 years of experience in woodworking (where I not only cut rebar, but also constructed playhouses, fashioned Kumiko jigs, and built decks and fencing) to help walk you through the essentials for slicing through rebar.
Keep reading to learn the 12 best, most time-tested strategies for cutting rebar!
Comprehensive Guide on How to Cut Rebar
Cutting through rebar can be broken down into two main phases: Gathering materials, and performing the cuts.
Let’s cover the material phase first:
What You’ll Need
The exact items you’ll need will depend on the method you choose, but this is a handy list of materials that all methods require:
- Safety goggles
- Gloves
- A mask
- A safe, clean workspace
- Your cutting tool (more on that later!)
- Measuring tape
- Chalk or crayon (for marking)
- A clamp or vice (to secure the rebar)
12 Effective Methods for Cutting Rebar
Without further ado, let’s look at our 12 strategies for how to cut rebar and find the best way to cut rebar for your project!
1. How to Cut Rebar with Angle Grinders
To cut rebar with an angle grinder, safety should always be the top priority.
I’ve found these to be one of the more dangerous tools on this list, and the fast-spinning wheels and flying sparks can wreak havoc if you’re not careful!
For performing the cut, simply use your tape measure and chalk to mark the cut, secure the rebar to the grinder, and turn on the tool, slicing along the path you marked.
2. Using Bolt Cutters to Cut Rebar
Smaller sections of rebar don’t necessarily require fancy machinery, and I’ve learned that a basic set of bolt cutters can often get the job done just fine.
The tactic here is to position the rebar between the blades and put pressure on the top handle with your hands to make the cut.
Be careful to watch out for sharp edges, as bolt cutters don’t tend to make clean cuts.
3. Cutting Rebar with a Circular Saw
Using a circular saw to cut rebar is one of my most common choices, and it’s extremely efficient.
After you measure and mark your cut, you can simply secure the rebar with a clamp or vise and use the saw blade to slice through the material.
4. Hydraulic Cutters for Cutting Rebar
Hydraulic cutters are one of the most optimal choices for cutting rebar, as the tool is simple to use and relatively safe.
My process for this method is to firmly secure the rebar between the two handles, and pump the movable handle to perform the incision with the cutter’s blade.
If you’re curious about hydraulic cutters, the YIYIBYUS 8T Cutter is one of the better choices.
5. Rebar Cutting with Rotary Hammers
A rotary hammer works exceptionally well for drilling through rebar because of the tool’s sheer power.
Making the cut is a straightforward matter of switching the machine to its rotation mode.
After that, just turn it on and let it drill!
6. Using a Rebar Cutting Machine
Dedicated rebar cutting machines naturally work quite well, and if you frequently cut rebar, it could be a good investment.
To work the machine, all that needs to be done is to place the rebar between the cutting mechanism and pull the handle.
7. Cutting Rebar with a Reciprocating Saw
Reciprocating saws work on rebar by using the tool’s “straight mode.”
After that, you can work the machine at a slow, steady speed.
With this method, I’ve found that these saws tend to be more ideal for small sections of rebar, as larger ones run the risk of blade damage.
8. How to Cut Rebar without Power Tools
If you don’t have any power tools on hand, a more old school approach is to use a hacksaw.
This process takes much longer than other, more sophisticated methods, but it has the advantages of lower cost and simplicity.
Much like other strategies I mentioned, using a hacksaw to cut rebar involves clamping the steel, marking the cutting point, and making slow cuts until the rebar is fully sawed.
9. Torches for Cutting Rebar
While a little unconventional, torches are entirely capable of cutting through rebar.
This option has the benefit of simplicity, since all you really need to do is point the torch at the area you want to cut and heat it until it separates.
But, there’s a drawback: If you’re not careful, cuts often end up jagged and imprecise!
10. How to Use a Miter Saw to Cut Rebar
Miter saws are more frequently used for cutting wood, but they can still slice through rebar in most cases.
I’d recommend this option if you don’t have any other power tools on hand, as it’s still far preferable to resorting to a hacksaw. Plus using a miter saw includes the advantage of allowing for precise, angled cuts.
11. Rebar Cuts with a Jigsaw
A jigsaw is a handy means of quickly cutting through a smaller section of rebar.
The device is trigger-operated with a blade positioned between its handles, ensuring precision cuts without taking much labor power.
The DeWalt 20V MAX XR is an excellent option for these types of cuts.
12. How to Cut Rebar with a Bandsaw
Though a bit bulky and slow, bandsaws can cut rebar with a very high degree of exactness, due to the minimal vibration the tool experiences during the cutting process.
To use a bandsaw for cutting rebar, you’ll likely want to avoid projects that require a huge number of cuts. The slow speed means this is an inefficient option for bulk projects, and is best reserved for a small amount of precise cuts.
Final Thoughts
Enjoy the guide, or did you find something missing? Either way, feel free to let us know in the comments!
Rebar plays a critical role in a huge range of woodworking-related projects, so I’m glad to share my hard-earned experience and knowledge to help others learn effective strategies for how to cut rebar safely, cleanly, and effectively.
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