Construction Material

Castellated Beams

Castellated beams are modified steel beam. In which the beam is cut in the central web portion were no great force is present. Cut near to neutral axis of the beam where we required less amount of material mass to resist various force.

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Castellated Beams

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What are Castellated Beams?

Castellated beams are made from standard hot-rolled I- H- or U-sections. The web of the beam is split lengthwise in a rack-shaped pattern. The halves so obtained are shifted a half-pitch in relation to one another and then welded together at the tops of the teeth. The result is a beam with a row of hexagonal holes in the body. The beam is much deeper than the original profile it is made from, while its weight is of course (almost) the same. It is also possible to weld square or rectangular plates between the cut halves, giving an even deeper castellated beam, now with octagonal holes in its body.


Castellated Beam



The castellated beam is not a relatively new invention. It was first utilized in the early 20th century, initially given the name of “Boyd beam”. Though modern innovations in this type of construction material have allowed the production of a variety of different patterns, it initially began with one pattern.

These kinds of beams were widely used throughout Europe in the 1950s, although this was mostly due to the overall lack of steel rolled sections. At this point, much of Europe was still rebuilding following the Second World War, so widespread access to steel (as well as affordable labor) was an issue. So in order to help stretch the amount of available steel and reduce overall , manufacturers took what rolled sections they had, split the sections in two, and then rolled the sections out utilizing the least amount of steel whereby producing a 30% to 40% stronger beam.


When is Castellated Beams needed?

Europe originally used the castellated beams because it had to. The lack of quality steel readily available gave construction teams very little choice in the matter.

Castellated beam geometric properties are typically thinner than standard steel rolled beams, yet the steel has not been compromised. Thick steel rolled beams can handle a considerable amount of weight, and most buildings do not put anywhere near the maximum weight on these beams. This means that a lighter, thinner weight can be used in the construction without compromising the structure’s stability. Because of the higher depth, the lighter, thinner beams are less expensive and consume less material, which can help save money during construction. They are also often stronger than the corresponding wide slanged section.

Castellated beams have a high strength-to-weight ratio, making them both cost-effective and long-lasting. So, what’s the point of using castellated beams? When a construction business seeks to save money without jeopardizing the structural integrity of the structure.


4 Advantages of Using Castellated Beams

  • Durability
    Through the physical alteration of the material – and in this case, steel is particularly used – the stiffness of the beam is increased, without having to make any changes to the material’s weight. The increase in depth also results in an increase in the level of vibration resistance that the newly-cut castellated beam can withstand, compared to the original, and un-manipulated beam.
  • Versatile
    As mentioned before, castellated beams have now been manufactured in a variety of different shapes and patterns. Though it initially was produced by particularly cutting up a zigzag, or hexagonal pattern on the beam’s rolled section, modern architectural innovations have allowed the production of castellated beams coming in different shapes. There now exists castellated beams with circular, rectangular, or even sinusoidal openings. While these different varieties exist, the other half of the rolled section is still attached in the same way, through welding. This is why one of the advantages of the castellated beam over its non-castellated counterpart, is that it offers a higher level of versatility.
  • Cost-efficient
    Another benefit of using castellated beams is that they are more efficient. It wouldn’t be farfetched to imagine that aside from completing a stable structure, one of the goals of construction companies is to avoid a blowout in their budgeting. Because a castellated beam is simply formed by combining the other half of a steel section to itself, no other complex chemical engineering is required. There is no need to chemically alter the internal structuring of the stainless steel material, in order to increase the strength. No other complicated and potentially expensive and time-consuming heat treatment procedures are required to change the grain properties of the beam.
  • Lightweight
    Finally, the castellated beam’s lightweight property is another one of the reasons why construction companies find the material highly-desirable. There would be no requirement of applying a complicated chemical manipulation of the material, as it is simply derived from components inherent within itself.Despite it being lightweight, this does not take away anything from the material’s strength properties. Nothing from the original beam is wasted in the process, if the material is cut evenly, all throughout.The lightweight material compounded with the increased level of stability it can potentially provide a structure is what makes it the more sought-after beam component in many construction undertakings.


Castellated Beams



The benefits of castellated beams in construction projects have been listed in the basic guide above. Its cost-effectiveness, durability, and versatility are only a few of the reasons for its widespread use in construction projects. Hopefully, the information presented above has persuaded you to use the castellated beam in more of your future construction projects.

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