Cutting Optimization in Rebar and Steel Profiles with Tasnifer

Importance of Cutting Optimization

In reinforced concrete structures, rebar is a critical component in terms of both structural safety and cost. Placing rebar according to the specified quantity and lengths in the project is essential for the expected performance of the structure.

Rebars are produced globally in standard lengths and are cut into required sizes from these bars. However, these cuts are often made randomly based on the experience and judgment of workers, without a proper cutting plan. This results in parts that are not used, incorrectly cut, or do not match project needs. These unused parts are called "waste" or "scrap." The same applies to steel profile cutting in structural steel projects.

Placing the cut part correctly is important not only for structural integrity but also for cost reduction. Reducing the amount of waste and increasing the efficiency of rebar usage is only possible through optimization at the cutting stage [1]. Moreover, both rebar and structural steels are costly and generate significant carbon emissions during production [2]. Therefore, reducing waste during cutting is also crucial for sustainability goals.

Rebar and Profile Cutting Optimization is a process that ensures cutting plans for rebar and steel profiles are prepared with minimal waste using mathematical optimization methods. This reduces costs, ensures ordering accuracy, improves labor efficiency, simplifies time management, provides quality assurance, and minimizes environmental impact.

Why Cutting Optimization is Necessary?

1. Cost Savings:

Although a 5% waste rate is considered acceptable, it often reaches 8-15% in practice. Even a 1% waste rate can mean hundreds of tons of wasted rebar in large projects. Studies have shown that there's a significant difference (usually over 5%) between cuts made using traditional site methods and those optimized using software.

2. Reduction of Carbon Emissions:

The carbon emission for producing 1 ton of steel varies by method but is generally accepted as 1.99 tons of CO₂ [3]. Any reduction in waste leads to a direct decrease in emissions.

3. Contribution to Sustainable Construction:

In green building certifications (LEED, BREEAM, etc.) and carbon credit systems, material optimization is seen as an advantage.

4. Efficient Use of Resources:

Rebar and structural steel are energy-intensive materials, even if recyclable. Reducing unnecessary production saves energy and preserves natural resources.

5. Labor and Time Efficiency:

Optimization shortens labor time on-site, reduces rework, prevents cutting errors, shortens project durations, and cuts labor and transport costs.

6. Predictability:

With traditional methods, it's hard to estimate the waste and order amounts before cutting begins. Optimization allows pre-cut calculation of these values, aiding stock and cost management.

7. Full Project Compatibility:

With optimization, each cut piece is matched to a specific position in the project, reducing the risk of errors and speeding up installation.

8. Digitalization and System Integration:

The software used for optimization can integrate with ERP/MRP systems and generate model-based cutting plans compatible with BIM.

The Solution: Cutting Optimization Software for Rebar and Steel Profiles – Tasnifer

In many countries, especially in recent years, efforts to improve efficiency and reduce emissions through cutting optimization have increased. Our company, operating under Gaziantep University Technopark, developed Tasnifer, a software solution designed based on industry needs and stakeholder feedback.

Figure 1: Example screenshots from Tasnifer

Tasnifer has been tested on numerous projects and proven effective. It ensures optimal cuts with minimal waste tailored to the project's needs.

Key Features of Tasnifer:

• Web-based, no installation required, accessible from mobile devices
• Minimizes waste in cutting rebar and steel profiles
• Directly imports quantity data from software like ideCAD, STA4CAD, Tekla Structures, etc.
• Accepts Excel-based data input
• Applicable to any structural project (buildings, bridges, retaining walls, etc.)
• Allows exporting quantity reports in Excel
• Categorizes and analyzes parts and quantities in detail
• Provides a waste list post-cutting
• Exports cutting plans in PDF and Excel
• Shows the position of each piece in the cutting plan
• Displays statistics (efficiency, order quantity, waste weight, etc.) before cutting
• Project-based pricing with full access to generated plans after payment

Rebar Projects:

• Allows ordering custom-cut rebars for low-efficiency parts
• Considers overlap lengths for rebars >12m
• Supports non-12m stock lengths
• Prepares plans across various configurations (floor, diameter, type, etc.)
• Reuses leftover pieces from one diameter as smaller sizes
• Sets a minimum acceptable length for leftover waste
• Calculates order quantity and efficiency by floor and diameter

Steel Profile Projects:

• Cuts from desired lengths for each profile type
• Keeps separate statistics for each type
• Tracks stock from previous projects and prioritizes reuse

Figure 2: Section from a sample cutting plan

Gains Achieved with Tasnifer: Comparative Analysis

The table below compares rebar usage from various literature projects using traditional methods vs optimization. It does not include Tasnifer’s advanced substitution feature (using leftover pieces from larger diameters in smaller ones). If included, Tasnifer would outperform competitors by a significant margin.

Table 1: Comparison of usage, efficiency, and emissions between traditional and optimized methods across projects

Project	Theoretical Weight (tons)	Site (tons)	Tasnifer (tons)	Site Efficiency (%)	Optimization Efficiency (%)	Profitability (%)	Reduction in Emissions (tons CO₂)
1	240,20	261,70	248,60	91,78	96,62	5,10	26,07
2	99,70	130,40	124,60	76,46	80,02	4,45	11,54
3	145,67	169,50	156,60	85,94	93,02	7,61	25,67
4	113,00	123,00	117,86	91,87	95,88	4,18	10,23
5	114,46	141,00	137,20	81,18	83,43	2,70	7,56
6	135,43	163,00	158,75	83,09	85,31	2,61	8,46
7	82,24	96,40	91,21	85,31	90,17	5,38	10,33
8	75,06	90,00	84,66	83,40	88,66	5,93	10,63
9	92,25	118,00	110,17	78,18	83,73	6,64	15,58
10	95,58	109,00	107,06	87,69	89,28	1,78	3,86
11	99,62	122,00	111,55	81,66	89,31	8,57	20,80
12	10,44	14,82	11,27	70,45	92,64	23,95	7,06

Global and National Impact

Global Impact

As of 2025, over 1.25 billion tons of rebar is expected to be used globally [6]. A 5% improvement could prevent around 188 million tons of CO₂ emissions.

National Impact (Turkey)

In 2022, about 19.56 million tons of rebar were consumed in Turkey [4]. A 6% savings via optimization could save 1.17 million tons of steel and prevent ~2.14 million tons of CO₂ emissions.

Considering the growing demand for rebar and structural steel, the savings and environmental benefits from Tasnifer are expected to increase.

Conclusion

Rebar and structural steel consumption is rapidly increasing worldwide. With over 1 billion tons used in construction projects, optimization can significantly reduce material costs, labor expenses, and emissions. It also enhances seismic safety, ordering accuracy, and international competitiveness.

References

1. Ren, K. et al. (2023) ‘Research on cutting stock optimization of rebar engineering based on building information modeling and an improved particle swarm optimization algorithm’, Developments in the Built Environment, 13, p. 100121. doi:10.1016/j.dibe.2023.100121.
2. Cucuzza, R. et al. (2024) ‘Sustainable and cost-effective optimal design of steel structures by minimizing cutting trim losses’, Automation in Construction, 167, p. 105724. doi:10.1016/j.autcon.2024.105724.
3. Steel - rebar emission factor Climatiq. Available at: https://www.climatiq.io/data/emission-factor/5cd03b14-6840-47e2-af28-4f363a4a856d (Access date: 26 July 2025).
4. Jassim, M. et al. (2021) ‘Trim Loss Optimisation for Construction Rebar Steel: Development of Decision Support System’, Academy of Strategic Management Journal, 20(5), 1-13.
5. Kamara, A. et al. (2022) ‘Optimization of reinforcement steel in building construction projects’, Available at: https://nce2022.ktimo.org/Content/images/dosyalar/c55e010d-2d77-4b40-aa9e-be7908e61191.pdf (Access date: 26 July 2025).
6. Widjaja, D. et al. (2024) Combined mechanical couplers and special-length-priority algorithm for reducing rebar consumption and cutting waste of beam reinforcement [Preprint]. doi:10.2139/ssrn.4703608.