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.
That said, professional masons recommend using a Diamond blade as it makes cutting rebar easier. Other blades such as the carbide tooth blade and tooth blades.
For heavy-duty cutting jobs like a steel reinforcing rod or pipe, a lower TPI would provide a coarser and quicker cut. An 18-teeth per inch blade would be the best choice. For a job that requires medium-duty cutting, like a thin wall electrical conduit, a 24-teeth per inch blade would do a better job.
The Reciprocating Saw
A reciprocating saw is another option. As with a hacksaw, you will need a suitable blade for cutting rebar – one with fine, sharp teeth. Being hand-held, recip saws can become tiring to use.
Metal blades with teeth – band saws, hacksaws, and sawzalls use relatively expensive metal blades. For small jobs, these work, but in my experience, these blades wear out too quickly to be a cost-effective way to cut large amounts of rebar.
Cutting rebar with a manual saw should be a last resort, but some will say that it is still a “creative way to finish a job.” You may be advised to secure the material properly in a vice and use a blade that won't easily dull (Yes, this method is particularly damaging to saw blades).
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.
Using an Angle Grinder to Cut Rebar
It's easy and versatile. You can cut rebar flush with concrete if it sticks out at all. It's also easy to cut any kind of angle you need.
The sharp edges of rebar can easily cut or puncture skin, and the metal can conduct electricity, which can cause serious injuries or even death. Wearing good cut-resistant gloves protects your hands from these dangers and helps you to avoid accidents.
These inexpensive saws are perfectly fine for cutting small pieces of mild steel (such as small-diameter rod, up to 3/8 inch) and small pieces of tubing (up to 3/4 inch).
A hacksaw is the best hand tool for cutting metal such as steel, copper, brass, or aluminum. It is also the plumber's choice for sectioning PVC pipes. However, it is not suitable for cutting through stone objects. Hacksaws work by running the teeth of the blade over the metal back and forth in a sawing motion.
For instance, if a rebar that is strengthening a steel beam structure within the slab is cut, this results in damage and the potential of having a falling structure. Similarly, if electrical conduits are cut then a shut down at the job site can happen or it may result in serious injuries.
A rebar cutter is a special tool designed to cut through reinforcement bars or structural steel components that add strength and integrity to concrete and masonry structures.
Do not forget that bolt cutters for rebar use a lot of force in order to perform the cut on these thick steel rods up to 16mm of thickness. This means that if you are cutting through smaller pieces of rebar, they can fly away from the rebar bolt and harm you.
Cutting torches are made to cut through metal, making them useful for cutting rebar.
The hydraulic-powered Lynx LCC31 concrete cutting chainsaw from Stanley Hydraulic Tools will cut concrete (wire or rebar reinforced), brick, block, masonry and stone.
An angle grinder is one of the most common tools for cutting steel. It is relatively inexpensive and easy to use. An angle grinder can cut through thick pieces of steel quickly and easily. However, it can also create dangerous sparks when misused, so take all necessary safety precautions when operating one.
Bar cutters, also known as 'rebar cutters' are the tools that are specifically designed to cut reinforcing steel bars. They allow builders to provide the right length of steel and provide the correct structural integrity. Cutting through any steel can be challenging due to the material's thickness.
Rebar is sized nominally by "eighths of an inch" of the bar's diameter. Every bar can be measured in eighths of an inch. A #3 bar is 3/8" in diameter.