how to make rebar chairs

How to Make Rebar Chairs: Step-by-Step Guide

By Andrew MooreNovember 15, 2025

Rebar chairs, also known as concrete chair blocks, are essential components in reinforced concrete construction. They provide support and spacing for steel reinforcement bars, ensuring the concrete can effectively encase and protect the rebar. Making rebar chairs involves a combination of metal fabrication techniques and understanding the principles of concrete reinforcement. This guide will walk you through the process, from selecting the right materials to the final finishing touches.

Before we dive into the step-by-step process, let's briefly discuss the types of rebar chairs. The most common types are: 1. **Adjustable Chairs**: These chairs allow for easy adjustment of the rebar spacing. 2. **Fixed Chairs**: These chairs maintain a constant rebar spacing and are typically used when precise spacing is crucial. 3. **Specialty Chairs**: These chairs are designed for specific applications, such as supporting rebar at corners or intersections.

Materials and Tools Needed

To make rebar chairs, you'll need the following materials and tools:

several chairs and tables are lined up in a room

a man bending over to look at a metal chair with four legs that are connected together

a child sitting on a bench made out of wooden slats and metal barstools

Galvanized steel sheet (for adjustable chairs)
Rebar (for fixed chairs)
Welding equipment (MIG or TIG welder, welding gloves, helmet, etc.)
Angle grinder with cutting and grinding discs
Tape measure and marker
Pliers and wire cutters
Drill and drill bits
Safety gear (safety glasses, ear protection, etc.)

a red chair sitting on top of a brown carpet next to a green table and chairs

two children are sitting at a table with chairs and one child is using a laptop

Make a Metal Workshop Stool on a Budget – from Rebar

Making Adjustable Rebar Chairs

Adjustable chairs provide flexibility in rebar spacing. Here's how to make them:

Cut the galvanized steel sheet into strips according to your desired chair size. A common size is 4" x 2".
Using the angle grinder, bend the strips at a 90-degree angle to create the chair's base and support.
Drill holes in the base and support strips for the rebar to pass through.
Weld the base and support strips together, ensuring they are perpendicular to each other.
Cut a long, thin strip of steel for the adjustment mechanism. Bend it into a 'U' shape and weld it to the chair's base.
Insert the rebar through the holes and adjust the spacing using the 'U' shaped strip.

Workshop Stool from Rebar - Plans and Dimensions

a set of six metal chairs sitting on top of a cement block in front of a white wall

Redwood Fence Office Table With Hairpin Legs

Build Stronger, Safer Structures with the Right Rebar Chairs!

Making Fixed Rebar Chairs

Fixed chairs maintain a constant rebar spacing. Here's how to make them:

Cut the rebar into short lengths according to your desired chair size. A common size is 6" to 12".
Using the angle grinder, bend the rebar at a 90-degree angle to create the chair's base and support.
Weld the base and support together, ensuring they are perpendicular to each other.
If desired, weld additional supports or crossbars for extra stability.

a man is working on a metal structure with two hands and one hand reaching for it

Rebar / Log Bar Stools -- Bancos De Bar Varilla / Troncos

a metal chair sitting on top of dirt covered ground

a wooden swing sitting on top of a wet parking lot

two lawn chairs made out of old tires sitting on the grass in front of a grassy field

two wooden barstools sitting next to each other on top of a cement floor

two metal chairs sitting next to each other on a white counter top in front of a cardboard box

many chairs and tables made out of old wooden slats are sitting in a garage

Cadeiras e bancos renovados com cordas - Joia de Casa

DIY Upcycled Chair Planter: Two Ways - Upcycle My Stuff

a table made out of metal pipes and some bottles on top of it in a room

Finishing Touches

After making your rebar chairs, it's essential to finish them properly to ensure they function correctly and last for a long time:

**Cleaning**: Remove any welding slag or debris using a wire brush or grinder.
**Galvanizing**: Apply a coat of galvanizing to protect the chairs from rust. This is especially important if you're using mild steel.
**Painting**: Apply a coat of paint to further protect the chairs and make them easier to identify on the job site.

Making rebar chairs is a straightforward process that requires basic metal fabrication skills. By understanding the principles of concrete reinforcement and following the steps outlined above, you can create high-quality rebar chairs that will enhance the strength and durability of your reinforced concrete structures. Happy building!