Rebar Bar Bending Schedule Software: How to Choose, With a Real Slab Example
A bar bending schedule (BBS) turns a structural drawing into a list the workshop can cut and bend: for each bar mark, the diameter, the number of bars, the shape, the dimensions, the cutting length and the weight. The software you use decides how many mistakes get into that list and how much steel is wasted when it is cut.
What the software should do
- Standard shape codes (for example BS 8666) with a drawing of every shape, so a bar cannot be misread.
- Cutting length with bend deductions, not just the sum of the dimensions.
- Weight per bar and per diameter, with the totals ready for the supplier.
- Print-ready sheets and an export to CAD (DXF) so the schedule can go back into the drawing.
- A cutting plan: which stock bars to buy and how to cut them with the least waste.
- Your language and your units, and a way to check every result by hand.
The main types of tools
| Type | Good for | Limits |
|---|---|---|
| Excel templates and calculators | A few bars, quick checks, full control of the formulas | Easy to break a formula; shapes are usually not drawn; no cutting plan |
| BIM and detailing platforms (for example Tekla Structures, Revit, Advance Steel) | Large projects modelled in 3D, schedules generated from the model | Heavy to learn and to license; the model must be built first |
| Dedicated BBS programs | Fast schedules from a bar list or drawing data | Differ widely in shapes, languages and export options |
| Cutting-stock (nesting) programs | Choosing stock lengths and cutting patterns | Need a clean list of pieces as input |
Where BarFlow fits
BarFlow BBS is an Excel workbook (Windows): type the bar mark, diameter, number of bars and a shape code, and it draws the shape, calculates the cutting length and the weight, prints the schedule and exports a DXF table for AutoCAD. BarFlow Cutting Plan is a separate small Windows program that takes the bar list and plans which stock bars to buy and how to cut them, with waste, weight, cost and a purchase order. Both work offline, have English and Arabic interfaces, and can be tried free. They are not a BIM tool: they do not read a 3D model, and every result should be checked before ordering or cutting steel. See the pricing.
A real slab: what the stock lengths changed
A real ground-floor slab (1,817 bars, about 8.2 tonnes: diameters 10, 12, 14, 16 and 20 mm) was planned three ways with BarFlow Cutting Plan, all with the same bar list:
| Stock lengths allowed | Bars bought | Waste | Steel bought |
|---|---|---|---|
| 12 m only | 985 | 23.8% | 10,753 kg |
| 6, 9 and 12 m | 1,056 | 7.2% | 8,873 kg |
| 4 to 10 m | 1,313 | 0.1% | 8,210 kg |
The difference between the first and the last plan is about 2.5 tonnes of steel for one slab. The trade-off is practical: more different lengths means more pieces to deliver, and 12 m bars need a larger truck and a crane on many sites. The figures are for this project and these lengths only.
A worked bend deduction
A U-bar in 12 mm steel with legs of 1160 mm and a back of 190 mm has two 90° bends. With a deduction of 4 × the diameter in total:
Adding the dimensions without the deduction (2510 mm) gives 50 mm too much on every bar; on 108 bars that is more than 5 m of steel. The exact deduction depends on the code you follow, so check yours.
Frequently asked questions
What is a bar bending schedule? The table that tells the workshop which bars to cut and bend for each part of the structure.
How is the cutting length of a bent bar calculated? Add the outside dimensions and subtract a deduction for each bend (see the example above).
How can I reduce rebar waste? Plan per diameter, combine pieces from different members and choose stock lengths that fit your pieces (see the slab example, and the guide to cutting with less waste).
Is there BBS software that works in Excel? Yes, BarFlow BBS (above).
Does it work in Arabic? Yes, both programs have English and Arabic interfaces.
Bar bending schedules in Excel and a rebar cutting plan, in English and Arabic. Both can be tried free.
BarFlow BBS (Excel)Cutting Plan (Microsoft Store)Pricing