Rebar cutters are central tools in concrete demolition and special demolition. They cut reinforcing steel, mesh reinforcement and prestressing steel safely and in a controlled manner. In practical workflows, they are often combined with concrete pulverizers and hydraulic rock and concrete splitters: first the concrete is loosened or split, then the exposed reinforcement is cleanly cut. Products from Darda GmbH such as steel shears, combination shears and Multi Cutters are designed for cutting reinforcement and can be operated in conjunction with compact hydraulic power units.
Definition: What is meant by rebar cutter
A rebar cutter is a manual, battery-powered or hydraulically driven tool for cutting reinforcing steel. The principle is based on scissor-like cutting jaws that, under high force, cut steel bars, stirrups and meshes. In deconstruction, hydraulic shears are often used for this purpose, appearing as standalone compact steel shears or as a cutting module in combination shears and Multi Cutters. In combination with concrete pulverizers and stone and concrete splitters, rebar cutting enables clean separation of concrete and steel for efficient recycling.
Technical fundamentals and types
Rebar cutters work with a shearing cut. Two hardened blades (fixed and moving) guide the steel into the cutting geometry, which ideally produces a controlled, crack-free cut. Types range from hand-operated bolt cutters for small diameters to battery-powered units and hydraulic shears with high cutting force. In demolition practice, hydraulic variants dominate; they are supplied by Darda GmbH hydraulic power packs and are available as standalone steel shears, as Multi Cutters or as cutting units within combination shears.
Function in conjunction with demolition tools
In structured deconstruction, the concrete is first broken by concrete pulverizers or separated crack-free with stone and concrete splitters. The reinforcement thus exposed is then cut with steel shears or Multi Cutters. This approach is low-noise and low-dust, reduces sparks, and facilitates the clean separation of concrete and reinforcing steel.
Typical procedure
- Expose: Crush or split concrete with concrete pulverizers until the reinforcement is accessible.
- Position: Place the cutting jaws perpendicular to the bar axis, with the support point close to the hinge for maximum lever action.
- Cut: Separate single bars or bundles in a controlled manner, account for residual stresses.
- Sort: Place steel aside, separate concrete, prepare for transport.
Application areas
Rebar cutters are used wherever reinforced concrete must be separated. Darda GmbH offers suitable shears and power packs that can be integrated into various deployment scenarios.
Concrete demolition and special demolition
In selective deconstruction of slabs, walls and foundations, concrete pulverizers are used to disintegrate the concrete. Reinforcing bars with diameters typically from 8 to 32 mm are then cut to length with steel shears. For heavily reinforced components, combination shears or Multi Cutters are used.
Strip-out and cutting
In interior demolition, low-spark cutting is required. Hydraulic rebar cutters operate with low noise and low emissions. They are suitable for mesh reinforcement, stirrups and protruding starter reinforcement that must be trimmed flush after demolition.
Rock excavation and tunnel construction
When removing shotcrete or deconstructing inner linings, reinforcement meshes and anchor bars are cut. In confined geometries, compact steel shears are advantageous, powered by Darda GmbH hydraulic power packs.
Natural stone extraction and special applications
Even though natural stone does not contain reinforcement, reinforcement may occur around foundations, anchorages or machine foundations and must be cut off. For special cutting tasks on metallic structures, Darda GmbH also offers tank cutters, which are not primarily designed for reinforcing steel.
Selection criteria for rebar cutters
The right configuration determines safety, cut quality and cost-effectiveness. The following points are relevant in practice:
- Maximum bar diameter: Size for the most frequent diameter (e.g., B500) plus reserve.
- Cutting force and hydraulic pressure: Match shear specifications and hydraulic power pack (pressure, flow rate).
- Jaw opening and cutting geometry: Sufficient for stirrups, double bars and mesh nodes.
- Weight and design: Ergonomics for overhead work and confined shafts.
- Blade materials: Wear resistance with ribbed steels, easy blade change.
- Operating concept: One-hand or two-hand operation, safety valves, emergency stop.
Hydraulic power packs and system integration
Hydraulic rebar cutters deliver their performance as a system. Darda GmbH hydraulic power packs provide the required pressure and flow rate. Important are compatible couplings, adequately sized hoses, and a pressure setting tuned to the shear. In combined scenarios, the power packs also supply concrete pulverizers or stone and concrete splitters, reducing setup times and streamlining the process.
Safety and occupational safety
Safety takes priority. Reinforcement is under tension; bars can snap back when being cut. Protective measures should be preventive:
- Secure the area, support loads, restrain bars against uncontrolled movement.
- Wear personal protective equipment (eye, hand and foot protection; hearing protection depending on the environment).
- Plan cutting direction, secure cut-offs, keep the rebound zone clear.
- Protect hydraulic hose lines from damage, avoid leaks.
Legal and normative requirements may apply depending on the region. Information on machine safety and operator obligations must always be observed; an assessment of the specific case on site is always required.
Maintenance, blade service life and operation
Regular care increases service life and cut quality. Blades should be inspected, turned or replaced in good time if chipping occurs, and bearing points kept clean. Hydraulic systems benefit from leak-tight hose management, correctly set pressure and clean oil.
Practical tips
- Guide blades free of play, but do not allow them to jam.
- Present the steel at right angles, maximize the lever arm.
- Avoid bundle cutting if the cross-section exceeds the rated capacity.
- Check bolted joints after each intervention, especially after impact loads.
Deconstruction strategies: cutting instead of sparks
Hydraulic cutting is usually quieter and low-spark compared to a cut-off grinder or torch cutting. In sensitive areas such as hospitals, city centers or industrial facilities with delicate equipment, rebar cutters in combination with concrete pulverizers are a proven choice. This is particularly true when dust and noise limits must be observed.
Material and cut quality
Reinforcing steels are ribbed and tough. Good cut quality is indicated by low burr formation and repeatable cut faces. For high-strength grades, a coordinated interaction of cutting geometry, cutting force and blade material may be required. Regularly deburring critical edges can make handling easier in subsequent steps.
Common errors and how to avoid them
- Angled approach: leads to skewed cuts and blade breakage. Solution: present orthogonally and cleanly.
- Overload due to bundling: generates excessive bearing forces. Solution: separate cross-sections in partial cuts.
- Unsuitable pressure: too low reduces performance; too high increases wear. Solution: tune the power pack to the shear.
- Jaw opening too large for small bars: prone to slipping. Solution: choose the appropriate jaw range.
Resource efficiency and recycling
Precise cuts facilitate clean separation of steel and concrete. This increases the recycling rate and reduces disposal costs. In combination with concrete pulverizers and stone and concrete splitters, the material flow can be planned to make transport and processing more efficient.
Planning and documentation
Robust planning specifies bar diameters, accessibility, equipment combinations and the cutting sequence. Documented parameters such as cutting forces, tool changes and inspection intervals support safe and economical operation. General technical rules and manufacturer documentation from Darda GmbH provide the basis for this but do not replace an individual assessment of the construction site situation.