There was quite a long discussion not too long ago with a member having a similar issue with the 255 bar limit. The solution is to simply render audio by smaller sections and compile the audio into one continuous song.

In Band in a Box:

Create a verse and chorus and export the audio. Repeat this three more times. Give each exported section a unique name and save them in a single location.

If you have the Windows Version, you can use RealBand. Open RealBand, import each section, one after the other to compile your song into 4 verse/chorus sequence. If you have a MAC version, you can compile your song in any DAW or even Audacity or similar program. RealBand also has the 255 bar limit if you attempt to render the entire song as a single piece of audio but that is no issue when working with audio. As long as you render sections of audio less than 255 bars, you won't have any issues.

Hope this helps.

BIAB 2025:RB 2025, Latest builds: Dell Optiplex 7040 Desktop; Windows-10-64 bit, Intel Core i7-6700 3.4GHz CPU and 16 GB Ram Memory.