How to Cut Rebar with Angle Grinder?

Rebar uses in most masonry projects to reinforce concrete structures. It supports concrete and provides extra strength. Since it comes in a certain size and shape, it has to be cut to the right size and bent depending on the project’s requirements. Sadly, rebar is a highly stubborn material that is difficult to handle. So what to use when it needs to be cut?

You can use a band saw, dermal, sawzall, etc. But I like to use an angle grinder to cut rebar, so I will include everything you need to know about cutting rebar with an angle grinder.

Best Angle Grinder Wheel for Cutting Rebar

The most important thing you need is a powerful angle grinder & right wheel for cutting rebar. Using the wrong one, like a ceramic cutting disc, will break and cause an accident. Before you start following the guide, you should make sure that you choose the right wheel/ abrasive disc.

Below is the list of a few recommended angle grinder wheels. It is worth using any of the following:

1. DEWALT DW8062B5 Cutting Wheel

The DEWALT DW8062B5 is a professional handyman cutting disc. It comes with a 4.5-inches diameter and 0.045-inches thickness. The wheel is best for cutting rebar and most metalwork, including grinding and polishing.

The best part is that this general-purpose disc offers burr-free cutting performance. It is because the disc is equipped with premium aluminum oxide. This high-quality material delivers fast and smooth cuts.

Besides, it offers maximum control over the cuts, and thus, you get burr-free cuts. It will last a long. You can use this durable disc to cut different materials, including aluminum, stainless steel, mild steel etc.

Benefits

• Best for light-duty to heavy-duty jobs
• Maximum rotating speed
• Smooth and fast cutting experience
• Durable
• Precise cutting experience

Drawbacks

• Not compatible with most grinder brands

2. S SATC Cutting Wheel 6″ Cut Off Wheels

S SATC 6″ cut-off wheel is designed to increase the efficiency of the angle grinder. The wheel offers a super-fast cut while retaining wheel life. Moreover, the exclusive ceramic grain mixtures of this 6-inch provide aggressive cutting action.

Besides, these high-performance ceramic grains keep the wheel sharp for a long time. It ensures quick and precise cuts. Moreover, the grain combination has a high density that allows for low-heat buildup and fast action.

This 6-inch cut-off wheel is designed to cut steel, fiberglass, plastic, rebar, sheet metal, etc. With the moderate power requirements, it gives you consistent reliability.

Benefits

• Better performance
• Ultra-thin yet more powerful
• Great cutting accuracy
• Fast and unmatched cuts

Drawbacks

• Due to its aggressive cutting action, it may not last long

3. LENOX Tools 1972921 4-1/2-Inch Cutting Wheel

If you want to use 1 disc for cutting all kinds of metals, then you must like LENOX 1972921. It will accomplish your needs. You can expect 1000 cuts of it. Moreover, advanced technology makes the wheel 30x more durable than thin-bonded abrasive wheels. The solid body of the wheel makes it highly resistant to wear and tear. It won’t break down even when the wheel operates at high speeds. The diameter of the blade will not change during its lifetime.

Overall, it enhances productivity and reduces interruption and cost per cut.

Benefits

• Most suitable for stainless steel or mild steel-related jobs
• Produce minimum dust
• Improve safety and minimize the risk of burns or injuries
• Can deliver more than 1000 cuts

Drawbacks

• Cutting speed is slightly slower than abrasive wheels

Best Way to Cutting Rebar Using an Angle Grinder

An angle grinder is possibly the best when it comes to cutting rebar. Experts suggest using it to get fast, neat, clean cuts. Using an angle grinder, you can use it to cut multiple parts of the rebar at once.

Nevertheless, it can cut rebar even when it sticks to concrete. It is more highly functional than many power tools. However, it generates sparks while cutting.

So everyone has to be prepared with necessary safety gear as follows:

• Long-sleeved shirt
• Long pant
• Work boots
• A pair of gloves
• Goggles

Moreover, work in a well-ventilated area for safe operation.

Then, follow the following 4 steps to cut rebar perfectly:

1. Prepare Your Angle Grinder by Setting Right Metal Cutting Wheel

At first, take a 4 ½-inch angle grinder with a powerful motor. Then, choose a diamond cutting wheel than can handle this metal cutting job. A diamond wheel is perfect for getting cleaner cuts in a minimum time.

The wheel will last longer than any abrasive blades. Make sure both the grinder and the cutting wheel are in good condition. Now set the cutting wheel into the grinder.

2. Mark the Cutting Position Where You Need to Cut

Now secure the rebar tightly using a vice or clamp. It is best to secure the rebar with two clamps on either side of the part you will cut.

Make sure there is enough space so you can move the tool freely. After securing the rebar in place, measure the part you need to cut. Use chalk to mark the position.

3. Set The Grinder to Maximum RPM

Switch on the grinder. Set it to maximum RPM. The speed should be between 3500 and 6000 RPM.

4. Start Cutting Slowing and Increase Pressure Gently

Now hold the grinder straight and make a straight cut following the predefined outline. The cuts in the rebar will not be perfect at the very beginning. It’s okay if you don’t get the perfect cut on your first attempt. Just try to ensure you are cutting on the line and avoid too much pressure. It can damage the blade as well as accidents. Later you can try grit accessories to smoothen the edges.

Final Words

Although you can cut rebar with a circular saw, hacksaw, rebar cutter, or bolt cutter, they will tire you out or take some time. Cutting tool misuse can damage the rebar. Thankfully, you now don’t have to think of those choices.

An angle grinder can do the cutting job like a pro within minutes. The tool is compact and can cut anything you want. It will reduce time in half and give your hands relief.

Follow the tool’s safety cautions, product guidelines suggested by the manufacturers, and follow what I described in 4 easy steps. Don’t rush and act carefully. By doing so, you can get a perfect and clean result with no issues.