Review Paper on Castellated Beam Systems

Abstract

Castellated beams have become an important innovation in steel construction due to their enhanced structural efficiency, higher strength-to-weight ratio, and economical use of material. These beams are fabricated by cutting and rejoining the web of rolled steel I-sections to create openings, which increase the depth and stiffness of the beam without adding extra weight. The web openings also facilitate the passage of utility services such as ducts, pipes, and electrical cables, thereby reducing floor height and improving architectural flexibility. This review paper presents a comprehensive study of castellated beams, including their fabrication methods, types of web openings, structural behavior, advantages, and failure mechanisms. Previous research studies on different opening shapes such as hexagonal, rectangular, square, and sinusoidal openings are reviewed and compared based on parameters like load carrying capacity, deflection, stress distribution, and buckling behavior. Special attention is given to the stress concentration developed around web openings, which is one of the major causes of failure in castellated beams. The review also highlights the application of Finite Element Analysis (FEA) and optimization techniques used by researchers to improve beam performance. Findings from the literature indicate that castellated beams significantly enhance bending strength and stiffness while reducing material consumption. Furthermore, sinusoidal web openings have shown improved structural performance by minimizing stress concentration effects compared to conventional hexagonal openings. This paper summarizes the latest developments and research trends related to castellated beams and provides guidance for future studies and practical applications in steel and Pre Engineered Building (PEB) structures.

KEYWORDS: Castellated beam, web opening