How To Cut Rebar With Angle Grinder?

If you are in the construction or metalworking industry, you may find yourself needing to cut rebar from time to time. Rebar, also known as reinforcement steel, is a common material used in construction projects to provide additional strength and support to concrete structures. It is made from steel and has a ridged surface that provides better adhesion to concrete.

Rebar is incredibly strong, which can make it difficult to cut. Fortunately, there are many tools available for cutting rebar to the desired length or shape.



  1. Angle Grinder

An angle grinder is a versatile tool that can be used for cutting, grinding, and polishing metal, wood, and other materials. They use a cutting wheel or a diamond blade for cutting through the rebar. They are affordable, portable, and can cut through thick rebar quickly. They also produce a smooth and precise cut that does not require any further finishing.

  1. Manual Rebar Cutters

Manual rebar cutters are hand-held tools that use a shearing action to cut through the steel bars. They are easy to use, portable, and do not require electricity or batteries. However, they are not suitable for cutting large or thick rebar, as they require a lot of physical effort and time. They also tend to produce rough or uneven cuts that may affect the integrity of the structure.

  1. Hydraulic Rebar Cutters

Hydraulic rebar cutters are powerful tools that use hydraulic pressure to cut through steel bars quickly and smoothly. They are ideal for cutting large or thick rebar, as they require minimal effort and time. They also produce clean and precise cuts that do not damage the rebar or the structure. However, they are relatively expensive and require a hydraulic power source, such as a pump or a generator.

  1. Plasma Cutters

Plasma cutters are high-tech tools that use a plasma arc to cut through metal, including rebar. They are fast, accurate, and can cut through thick rebar without any effort. They also produce a clean and smooth cut that does not require any further finishing. However, they are expensive, require a lot of maintenance, and produce a lot of heat and sparks that can be hazardous to the operator and the surrounding area.

  1. Abrasive Saw

An abrasive saw is a handheld or stationary tool that uses an abrasive cutting wheel to cut through steel bars. They are relatively affordable, portable, and can cut through thick rebar quickly. They also produce a smooth and precise cut that does not require any further finishing. However, they produce a lot of dust and noise, which can be harmful to the operator and the environment. They also require frequent replacement of the abrasive wheel, which can be costly.

Recommendation: Angle Grinder

Of all the tools discussed above, the angle grinder is the most recommended tool for cutting rebar.

Angle grinders are widely used in construction projects due to their versatility, affordability, and ease of use. They can be equipped with various types of cutting wheels or blades, including diamond blades, abrasive discs, and metal-cutting wheels. They also come in different sizes and power ratings, depending on the type of job and the thickness of the rebar.

Advantages of cutting rebar with an angle grinder

  • Portability

Unlike hydraulic cutters or plasma cutters, angle grinders do not require a power source or a bulky equipment setup. They can be carried by hand or mounted on a stand or a bench, depending on the size and weight of the tool. This makes them ideal for cutting rebar in tight spaces, such as corners, walls, or ceilings, where other tools may not fit.

  • Speed and efficiency

Angle grinders can cut through thick rebar in seconds, depending on the size and power of the tool. They can also produce a smooth and precise cut that does not require any further finishing, unlike manual cutters or saws. This can save a lot of time and effort for the operator and the construction team, especially if the project involves a lot of rebar cutting.

Guide For Using Angle Grinder To Cut Rebar

Angle grinders is a useful tools indeed. However, it can be dangerous if not done correctly. Now, we will provide a step-by-step guide on how to cut rebar with an angle grinder safely and efficiently.

  1. Gather the necessary tools and safety equipment

Before using an angle grinder to cut rebar, make sure you have all the necessary tools and safety equipment. You will need an angle grinder, a diamond circular saw blade, a cut-off wheel, safety glasses, gloves, earplugs, and a dust mask. It is essential to wear all safety equipment to protect yourself from flying debris and dust.

  1. Choosing the Right Blade

Before using an angle grinder to cut rebar, it is important to choose the right blade. The most common types of blades for cutting rebar are abrasive metal cutting discs and diamond circular saw blades. Abrasive metal cutting discs are made of abrasive grains bonded together with a resin, and are generally cheaper than diamond circular saw blades. However, they tend to wear out quickly and generate a lot of heat, which can cause the rebar to warp or even break.

On the other hand, diamond circular saw blades are made with a metal core and diamond particles embedded in the rim. They are more expensive than abrasive metal cutting discs but offer several advantages. Diamond circular saw blades are designed to cut through hard materials like rebar, and they generate less heat and produce less dust. This makes them a safer and more efficient option for cutting rebar.

  1. Preparing the Angle Grinder

Before you start cutting, it is important to properly prepare your angle grinder. Begin by inserting the diamond blade into the grinder and tightening it securely. Next, check that the blade is properly aligned and not wobbling, which could cause an uneven cut or damage to the blade.

Once the blade is secure, put on your safety gear. This should include eye protection, gloves, and a dust mask. Rebar can produce a lot of dust and debris when cut, which can be harmful to your eyes and lungs. Additionally, gloves can protect your hands from the heat generated by the grinder and the sharp edges of the rebar.

  1. Setting Up the Cut

Before you start cutting, make sure the rebar is securely clamped down. This will prevent it from moving during the cut, which could cause an uneven cut or result in injury. You can use a vise or C-clamp to secure the rebar to a workbench or other stable surface.

When setting up the cut, mark the rebar where you want to make the cut. This will ensure that the cut is straight and accurate. You can use a permanent marker or a piece of chalk to make the mark.

  1. Making the Cut

To begin the cut, turn on the angle grinder and allow the blade to come up to full speed. Then, slowly lower the blade onto the rebar, making sure to follow the marked line. Apply gentle pressure as you cut, allowing the blade to do the work.

When cutting, it is important to keep the angle grinder steady and avoid tilting it or twisting it. This could cause the blade to bind, which could be dangerous and cause the grinder to kick back. Additionally, it is important to let the blade cool down periodically to prevent overheating.

If you need to make a curved cut, a circular saw attachment for your angle grinder can be a useful tool. A circular saw attachment will allow you to make more precise curved cuts and can save you time and effort. To use a circular saw attachment, simply attach it to your angle grinder and follow the manufacturer’s instructions.

  1. Finishing the Cut

Once the cut is complete, turn off the angle grinder and allow the blade to come to a complete stop before removing it. Then, remove the clamps and examine the cut for accuracy. If necessary, use a metal file to smooth out any rough edges or imperfections.

Finally, clean up the work area, including the dust and debris produced during the cut. Properly dispose of any scraps of rebar or other materials, and store the angle grinder and diamond blade in a safe location.


Knowing what tool to use to cut rebar, rebar cutting could be an easy thing.  An angle grinder can be an effective tool for cutting rebar, but it is important to take proper safety precautions and follow best practices for a safe and successful cut. Choosing the right blade, such as a diamond circular saw blade or a cut-off wheel. Follow the step-by-step guide outlined in this article to ensure that you are cutting rebar safely and efficiently. With the proper technique and equipment, you can safely and efficiently cut rebar to the required size and shape for your construction project.


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