How to Cut Rebar With Angle Grinder

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Reinforcing bars, or rebars as they are more commonly known, are steel bars used in reinforced concrete and masonry constructions to protect against tension and strengthen the concrete. It aids in mitigating the typically low tensile strength of concrete. The entire structure is strengthened by increasing the tensile strength of the concrete and concrete products, which also lowers the likelihood of slippage.

Due to its virtually identical thermal expansion to concrete, steel is commonly used for rebars. Rebar is typically produced in lengths greater than 50 feet; because different constructions have differing length requirements, cutting them to the appropriate lengths for the structure being worked on is practical.

The angle grinder is one of the most versatile tools for cutting rebar; hence it’s most commonly used. Unlike hacksaws, you don’t have to worry about excessive wear or tear from friction and pressure or have to replace the sharp blades after a short period of usage. It reduces the time and effort used in cutting rebar, making it less labor-intensive.

You can use several power tools to cut rebar. These power tools include a chop saw, an angle grinder, a hacksaw, bolt cutters, and an acetylene torch. Each tool’s level of efficiency, degree of usage, and total outcome vary. We will, however, go through how to use an angle grinder to cut rebar in this article.

Why Should You Use an Angle Grinder?

Power tools like the hacksaw are frequently advised when cutting most metal or steel materials. However, when cutting rebar, they become ineffective and detrimental. Rebar puts a lot of strain and friction on the power tool’s blade, which can cause rapid deterioration. Repairs and replacements would need to be done frequently. In addition to the effect on the tool, the operator feels the strain from the added work that has to be done.

Angle grinders greatly eliminate these effects and provide simplicity of use while working with rebar thanks to their compact size and smooth operation. They have a geared head with an abrasive disc or cut-off disc mounted on it, all powered by an electric motor or compressed air. Widely used in construction sites and metal fabrication shops, they are the ideal tool for working rebar without hiccups.

Factors to Consider Before Using an Angle Grinder

There are certain factors you should consider before using an angle grinder. These factors are essential and will determine how easy and smooth your work will be.

The Right Size

Getting the right size goes a long way in determining the effectiveness when cutting a piece of rebar. A small size is suitable for precise cutting, while you can use a larger one for general cutting and grinding. It is advisable to use a grinder between 4 to 4½ inches, as it can handle most jobs.

Quality of the Angle Grinder

To ensure long-term use, buy a grinder of superior quality. Cheap models are not recommended since they break easily. You may end up with broken discs, damaged blades and wheel guards, and other broken parts. Apart from durability, cheap grinders produce shabby cuts due to the low quality of their parts. Angle grinder quality greatly affects how precise your cuts are, and its importance cannot be overemphasized.

Working Angle

The angle at which you use your grinder substantially affects the quality of your cuts. Choose the appropriate viewpoints to adopt. Make sure there is a 20 to 30-degree angle between the angle grinder and the work surface, depending on where you want to cut the rebar, and then carefully move the rotating disc over the rebar.

Cutting Technique

Pay close attention to how the rebar is cut. A grinder is a handy tool, but using it well requires the appropriate technique, which takes practice to learn and master. With the proper technique, your cuts are more precise and cleaner. It also saves you time and resources that you may lose if your cuts come out worse than desired.

Size and Type of Disc

The size of the disc determines the type of work you can do. Small discs are made for finer work, while larger discs are used for heavy-duty works like cutting rebar, angle irons, or rusted bolts. There are seven types of discs: grinding wheel, flap disc, cut-off wheel, wire wheel, strip disc, ceramic disc, and ceramic sanding disc. Each disc has its use, strengths, weaknesses, and the amount of rebar it can cut before wearing out. Ensure you know the correct disc to use for each job.

How to Cut Rebar With Angle Grinder Grinder Power Tool

How to Cut Rebar with an Angle Grinder

Before you cut rebar, consider the factors above. Most importantly, ensure you have the right type of disc, as it determines how precise and less tedious your cuts are. To efficiently use an angle grinder, you should follow the following steps:

Safety Check

Perform a safety check before you begin. Sparks fly when you use an angle grinder, so be sure your surroundings are free of any flammable materials. Wearing protective gear like earplugs, goggles, fireproof gloves, or safety gloves is also advised.


Use a vice or clamp to secure the rebar in place and make sure there is no movement. The risky alternative of holding the rebar with one hand and operating on it with the other is no longer an option because you need both hands to operate the angle grinder.


Mark the rebar with chalk or pencil. Carefully measure the rebar and make markings on the areas to be cut. Making an outline guarantees precise cutting. It also keeps your work professional and coordinated and prevents mistakes.

Work the Grinder

Start up your angle grinder. Slowly move it closer to the rebar when it is at maximum speed. Work it from top to bottom by touching the spinning disc to the rebar to get a clean cut.


After cutting, smooth out the jagged edges with the help of a sanding or grit accessory. Ensure you do not let go of the angle grinder during cutting to avoid injuries and accidents.

We’ve seen the steps to take when cutting rebar with an angle grinder. If you follow these steps and the guidelines above, cutting your rebar will be a piece of cake.

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