How to Cut Steel Bars

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Unless you're trying to break out of prison, cutting steel bars is a very easy process with the right tools. Some say that it's possible to cheaply cut steel bars with a mitre saw and an abrasive chop saw disk, but that method is a dangerous undertaking. Before cutting steel bars, take time to procure the right supplies. Doing so will cost you less aggravation and lead to a better, safer and cleaner cut.

Things You'll Need

  • Horizontal metal-cutting band saw or cold saw or chop saw
  • Protective goggles
  • Heavy-duty gloves
  • Steel bar
  • Grease pencil
  • Mark your anticipated cut on the steel bar with the grease pencil.

  • Place the marked steel bar squarely on the cutting platform of the saw. The safest, more efficient and easiest saw to operate is a cold saw. Secure any fasteners or holders that are on the platform to ensure that the steel bar does not slip during the cutting process.

  • Put on the safety goggles and heavy-duty gloves.

  • Turn on the saw. Make sure the blade is running smoothly and evenly.

  • Grip the saw handle with your dominant hand. Secure the steel bar using your non-dominant hand. Make sure you are holding the steel bar at a safe enough distance from the blade of the saw.

  • Press down on the saw with a smooth, slow motion. Do not stop pressing until the saw has gone through the bar entirely.

Tips & Warnings

  • If you are cutting with a band saw or a hot saw, always operate away from any flammable material as the sparks will fly when you are cutting! Never put any part of your body near the blade of the saw while it is running. Never try to cut more than one bar at at time.

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  • Photo Credit Paul Mihalides
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