How to Prepare a Rebar Cutting List

What Is a Rebar Cutting List?

A rebar cutting list — also called a bar schedule or bending schedule — is the procurement and fabrication document that translates structural reinforcement drawings into specific bar marks, diameters, lengths, bending shapes, and quantities. Every bar on every drawing gets a unique mark; the schedule collects them all into a tabular list that mills, stockholders, and fabricators use to cut, bend, and tag steel before it reaches your site.

For international projects supplied with German-standard rebar, the cutting list drives mill order quantities, helps verify Mill Test Certificates against actual bar sizes, and ensures that B500B or B500C grade bars arrive in the right dimensions with no shortfall. Getting it right the first time avoids costly re-orders and construction delays.

Reading the Structural Drawings First

Before writing a single line of the schedule, gather and reconcile all reinforcement drawings. Key items to identify:

• Bar marks — unique alphanumeric codes (e.g. T1, R2, B3) assigned to each distinct bar type.
• Diameter (d) — typically 8 mm to 40 mm for structural elements; check each detail carefully.
• Shape code — the bending geometry, referenced to DIN 488 shape codes or BS 8666 if specified.
• Dimensions A, B, C, D, E — straight leg lengths between bends, measured to the outside of the bar.
• Number of members — how many beams, columns, or slabs use this bar mark.
• Bars per member — the count of that mark within a single element.

Calculating Cut Lengths — The Core Method

The cut length is the total length of straight bar before bending. For a bent bar it is NOT the sum of outer dimensions: each bend consumes extra material. The standard deduction per 90° bend is approximately 2d. For a 135° hook, deduct approximately 3d.

Example — a U-bar with legs A = 300 mm, B = 600 mm, A = 300 mm, two 90° bends in 12 mm bar:

• Sum: 300 + 600 + 300 = 1,200 mm
• Deduction: 2 bends × 2 × 12 = 48 mm
• Cut length: 1,200 − 48 = 1,152 mm

Worked Example — Foundation Pad

A 2,000 × 2,000 mm pad footing with 12 mm B500B bars at 200 mm centres, 50 mm cover:

Weight: kg/m = d² × 0.00617. 12 mm bar = 0.888 kg/m. Total indicative ~58 kg. Engineering verification required.

Adding Laps, Hooks, and Anchorage Lengths

Straight bars that need to be lapped add to the cut length. Under Eurocode 2 / DIN EN 1992-1-1, the design lap length (l₀) for B500B in C25/30 concrete typically ranges from 40d to 60d — 480 mm to 720 mm for a 12 mm bar. This lap must be included in the cut length of the lapping bar.

Organising the Schedule Table

A well-formatted cutting list typically contains: member reference, bar mark, number of members, bars per member, total bars, diameter, shape code, dimensions A/B/C (mm), cut length (mm), total linear metres, unit weight (kg/m), and total weight (kg). Sort by diameter, then bar mark within each group. For export procurement, provide the summary by diameter so that tonnage per size can be confirmed against available stock lengths of 6, 9, 12, or 18 m.

Common Errors to Avoid

• Forgetting cover: bar dimensions should be clear cover dimensions minus the specified cover (e.g. 35 mm for foundations).
• Double-counting lap bars: the lap length is in the cut length, not a separate bar mark.
• Mixing shape code standards: DIN 488 and BS 8666 shape codes differ — confirm which applies.
• Omitting waste allowance: add 3–5% uplift at procurement. See our guide on rebar wastage and lap allowance.
• Not confirming stock lengths: a 10,500 mm cut from a 12 m stock leaves a 1,500 mm offcut — wastage rises sharply.