Methods for bending 3/8" rebar in different OD's?

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I've got a little under 200 rings to make out of #3 (3/8") rebar to 20" OD, 14" OD, and 10" OD. What is the fastest and easiest method for doing this?John 3:16(2) Miller Pheonix 456(2) Millermertic 252Dynasty 210DXHobart 210MVPDoringer D350 SA Cold SawScotchman 350LT Cold SawWebb 10x50 MillWebb 15x40 LatheGeka Bendicrop Ironworker
Reply:I'd simply go talk to my concrete form and material supplier and have them roll the bars on their roller they use to do spiral rebar for columns. They can roll pretty much whatever diameter  and spacing I'd need done. Then I'd cut all the "rings" loose and weld them together. It wouldn't surprise me at all if their automated machine couldn't cut all the rings individually and save me that hassle as well. I'm betting there is a place like that where you are.Doing it myself, I'd probably want to try and wrap it around a pipe with the right diameter, then cut the rings loose. The trick would be getting the OD of the pipe right to match with the spring back of the rebar. A length of 1/2" or 3/4" pipe slid down the rebar will give you the added leverage to make this easy and concentrate the bending where you want it. If diameter was really critical, I might have to make the center form from a couple sheets of stacked plywood so I could easily adjust the size, and roll individual rings one at a time.If a "lumpy" shape doesn't matter, they could be "bump" bent with a rebar bender. Keeping the bar aligned after you start bending is the tough part. A sheet of plywood vertical the bar can rest against will help maintain a consistent position when changing the bar for each bump.  It wouldn't be too bad for a small quantity, but not really my 1st choice for repeatable quantity..No government ever voluntarily reduces itself in size. Government programs, once launched, never disappear. Actually, a government bureau is the nearest thing to eternal life we'll ever see on this earth! Ronald Reagan
Reply:Originally Posted by DSWI'd simply go talk to my concrete form and material supplier and have them roll the bars on their roller they use to do spiral rebar for columns. They can roll pretty much whatever diameter  and spacing I'd need done. Then I'd cut all the "rings" loose and weld them together. It wouldn't surprise me at all if their automated machine couldn't cut all the rings individually and save me that hassle as well. I'm betting there is a place like that where you are.
Reply:These guys listed bending/rolling rebar on  a quick Google search.http://www.cmrp.com/bar_bending.htmlhttp://mccannonline.com/serv_rebar.htmlThese guys look like they have a couple locations in the Chicago area. I'd bet they can roll what you want if they don't have something in stock.http://www.harrisrebar.com/I'd suspect with a big city like Chicago there's at least one major concrete materials supplier like VIMCO here in Philly who rents/sells forms, stocks bar/wire, has form plywood, concrete tools etc. The question is just figuring out what search terms pulls the places up. If nothing else, a call to the local ready mix companies may give you a line on who to talk to in your area.http://www.vimcoinc.com/A lot is going to depend on just how strict what you are doing is. I used to be really good at bending up square stirrups for columns. It would take me two or three test bends to get all my dimensions and layout marks right on our manual bar bender, mostly because I didn't do that stuff every day, but once I was all dialed in I could knock them out pretty fast within 1/4" or so of each other. Key was just finding a point on the bender I could use as my gauge to start my bends. Slide the mark on the bar to my start point, bend, slide to my next mark to the start point and repeat. If I was doing a ton all the same size, I'd often even use a fixed stop in front of the bender. Pretty much slide to my stop and bend, repeat...Most of the time for doing light posts, small columns for decks etc, the Architect/engineer really didn't care if we used square or round "rings" for reinforcement. I can only really think of one job where they continuous specified spiral reinforcement, but we don't have quite the seismic requirements they have in places like Cali. and so on where that is now required..No government ever voluntarily reduces itself in size. Government programs, once launched, never disappear. Actually, a government bureau is the nearest thing to eternal life we'll ever see on this earth! Ronald Reagan
Reply:http://www.gerdauameristeel.com/loca...joliet_loc.cfmThese company has a location in Decatur Il and can roll what ever size ring you need.  The link is for thier location in Joliet Il.Dan D.Manipulator Of Metal
Reply:Look for construction supplies. White Cap is who I used to use locally.GravelThe difference between theory and practice is that in theory there is no difference.
Reply:I agree with the idea of wrapping it around a pipe of the correct diameter. That's probably what I would try if the correct machine wasn't available.Andrew
Reply:This is how I made some 16" circles out of 3/8" rebar for a garden arbor project.  Had to re-tack the bar to the pipe.  The rebar will recoil so you'll have to measure for the correct circumference, cut and force ends into shape before welding.However, for just under 200 pieces I'd be inclined to check with the concrete form company as DSW suggested.Last edited by duaneb55; 04-04-2015 at 07:50 PM.MM200 w/Spoolmatic 1Syncrowave 180SDBobcat 225G Plus - LP/NGMUTT Suitcase WirefeederWC-1S/Spoolmatic 1HF-251D-1PakMaster 100XL '68 Red Face Code #6633 projectStar Jet 21-110Save Second Base!
Reply:Same method as Duane, except instead of welding it to the pipe I welded a piece of angle to the pipe.  Just stick the end of the rebar under the angle and bend the hoop, and slide the other end under the angle and weld, then cut the excess. 200 + you are going to be sore!!
Reply:Just looking at some videos of those rebar spiral bending machines. I think I could make one for pretty cheap. I have an extra motor laying around I could probably use. I don't think it would take that long to make something. But I'll get a quote first from local suppliers on rolling the rebar.John 3:16(2) Miller Pheonix 456(2) Millermertic 252Dynasty 210DXHobart 210MVPDoringer D350 SA Cold SawScotchman 350LT Cold SawWebb 10x50 MillWebb 15x40 LatheGeka Bendicrop Ironworker
Reply:I have a jig for turning rod in my lathe. It works pretty good, but you need a bigger sized lathe to handle it and I dunno if you have one or not. You can make the rings whatever size you want up to the diameter of pipe you can fit in the chuck. It forms a coil like a spring, then you just cut the rings free like Doug said. The pipe with a hole in it forms the rings, then I use an 1 1/2" bar I machined the end of in a rigid tool holder as a guide to hold the rod down and force it over the pipe as the chuck turns. I run it in reverse to do this. It actually works pretty slick, the rings are very round and you can get quite a few on the small form I have. You could prolly run a longer one between centers and make a couple dozen at once.I would have someone do it for you that has a machine to do it. Lots easier than screwing with it if you don't have the stuff to do it economically.Expert Garage Hack....https://www.facebook.com/steven.webber.948
Reply:Just clicked those links you gave me, DSW. McCann is right across the street from me! Never knew what they did... Funny how that works.John 3:16(2) Miller Pheonix 456(2) Millermertic 252Dynasty 210DXHobart 210MVPDoringer D350 SA Cold SawScotchman 350LT Cold SawWebb 10x50 MillWebb 15x40 LatheGeka Bendicrop Ironworker