How to Bend and Cut Rebar

Last Updated: February 19, 2023

Bending and cutting rebar (steel concrete reinforcing bars) is often necessary when building structural reinforcement for concrete work. It is an easy to work with material that is commonly used in landscaping, art, and other projects where metal that is fairly easy to bend is required. Common rebar is sold by its diameter in 1/8th inch increments (meaning "#4" rebar is 1/2 inch in diameter). Rebar up to #4 can often be bent and cut by hand. Larger diameter rebar is not typically used outside commercial or industrial concrete work and usually requires specialized equipment such as hydraulic shears and benders.

In this article we will assume the use of 1/2 inch (number 4) rebar which is a common rebar found in residential landscaping and concrete work.

Steps

1
Have the right safety equipment. Rebar can be sharp and is heavy, and can create sparks when being cut. Always wear eye protection, sleeved shirts, long pants, gloves, and sturdy boots when handling rebar.
2
Setup a workspace. Rebar comes in very long rods (typically 8–20 foot and up to 40 foot in length). Due to its length, tendency to be covered with mill scale or rust, and overall weight rebar is usually best handled in a large open area with few obstructions. Cutting rebar often creates very hot sparks so make sure the area is clear of flammable materials. The rust and sparks from rebar can ruin clothing so wear something sturdy and old.

Advertisement
3
Measure carefully. Taking into account the overall length, any overlap (where you might tie it to another piece), and especially the curves can be a bit tricky. You may find that the first few times you bend and cut a piece of rebar it is shorter or longer than you had intended. This is often due to a failure to account for the length of the rebar through the curve. It can be tricky but you'll get the hang of it. Rebar is very easy to mark with wax crayon (if you'd like waterproof marking) or chalk (often handy in art projects where you'd like the marks to wipe off).^{[1]
X
Research source}
4
Cut your rebar. Cutting rebar can be done easily with a metal cutting hacksaw blade. You can also use a reciprocating saw, portable bandsaw, or grinder equipped with a blade suitable for cutting "mild steel".^{[2]
X
Research source} Rebar tends to want to roll around when being cut, therefore it is often necessary to step on the bar or have an otherwise steady hold while cutting it. Cut rebar is always hot and/or sharp. Use gloves and caution.
5
Bending rebar ¹⁄₂ inch (1.3 cm) or smaller. Now that you have a piece cut to length it is time to bend it. Bending rebar is all about leverage. Place the rebar on the ground. Using a long metal pipe with a large enough internal diameter, place the rebar into the pipe stopping about six inches from the point you'd like to start the bend. Place your foot 6 to 12 inches (15.2 to 30.5 cm) back from where you'd like to bend. Pressing firmly down with your foot, raise the bar off the ground until the bar bends to the angle you'd like. It is often necessary to bend a piece a little at a time if you are trying to get an exact bend.^{[3]
X
Research source}
6
Other methods and tools. You can rent simple manual rebar benders at most hardware stores.^{[4]
X
Research source} If you have a lot of cuts to make renting a metal chop saw is often the most efficient way to cut a lot of rebar.

Community Q&A

Question

If I change the direction of the bend does this affect the integrity of the bar?

Community Answer

No. Direction of the bend does not change the integrity of the bar. Repeated bends at the same point, however, will weaken the metal.
Question

Is possible to re-bend a rebar at the same point that it has been bent previously?

Community Answer

Yes, rebar is very soft iron and does not crack easily. It can be straightened and then re-bent.
Question

How do I know how much rebar I need for the reinforcement of a structure?

Community Answer

That depends on the design. Basically, it varies from 1 to 4% of rebar in concrete quantity.

Warnings

Using heat to assist in bending rebar can substantially weaken the rebar.

⧼thumbs_response⧽
Helpful 0 Not Helpful 0
Cutting rebar, especially with an abrasive cutting wheel creates very hot sparks. These sparks will burn exposed skin and are very hazardous to your eyes. Always wear long sleeve shirts, gloves, and safety glasses when cutting any type of steel.

⧼thumbs_response⧽
Helpful 0 Not Helpful 0
Rebar is often rusty. If you get cut while working with any rusty metal it is possible that you may need a tetanus shot. See your health care provider.

⧼thumbs_response⧽
Helpful 0 Not Helpful 0