Question 1

How accurate are calculated round bar weights?

Accepted Answer

Theoretical weights assume nominal diameter and standard density. Actual mill tolerances introduce ±2–3% variation. For inventory valuation, theoretical weight is acceptable. For shipping or load calculation, use actual weigh scale reading.

Question 2

Does hex bar use the same formula?

Accepted Answer

No. Hex bar weight = (Width across flats² × 0.866 × 0.222) for steel, per foot. The 0.866 factor accounts for the hexagonal cross-section being 86.6% of the circumscribed circle area. Always use the specific hex formula rather than approximating as round bar.

Question 3

How do I account for cut-off and saw kerf in length estimates?

Accepted Answer

Subtract 0.125–0.250 inches per cut for saw kerf plus an additional 0.5–1.0 inch for end cleanup from the original bar length. For high-value materials like stainless or brass, marking and tracking cut-off drops can recover 2–5% of material cost.
⚡ Calculated for Carbide-Tooling.com High-Performance Series. View Catalog →

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