What is a castellated beam?

A castellated beam is a structural steel beam that has been modified by cutting a series of hexagonal or circular holes along its web, then welding the two halves back together in a way that increases the overall height of the beam. This creates a unique honeycomb pattern, making the beam lighter while enhancing its load-bearing capabilities. Castellated beams are widely used in construction projects that require strong yet lightweight materials, offering a range of benefits and versatile applications.

Advantages of Castellated Beams

1. Increased Strength with Less Weight

The cutting and reassembly process increases the beam’s height, which enhances its ability to handle larger loads without significantly increasing its weight. This makes this type of steel beams a more efficient alternative to solid beams of the same height.

2. Material Efficiency

The perforated design reduces the amount of steel needed to fabricate the beam, making it a cost-effective option for construction projects. The reduced material usage also makes these beams more environmentally friendly, as they require less steel production.

3. Easier Integration of Utilities

The openings in the web of castellated beams allow for easier integration of electrical wiring, plumbing, and HVAC systems. This makes them ideal for projects where the concealment of utilities is necessary, such as in commercial buildings or residential loft conversions.

4. Aesthetic Appeal

With their distinctive open-web design, these steel beams offer an architectural advantage. Their visually striking appearance makes them a popular choice for architects looking to expose structural elements for industrial or modern interior designs.

5. Versatility in Applications

These beams are versatile and can be used in various structural applications. Their lightweight nature allows for greater flexibility in design, making them suitable for a wide range of construction projects, including those with longer spans or where reducing the overall weight is a priority.

Types of Castellated Beams

1. Hexagonal Castellated Beams

These beams have a series of hexagonal holes cut into their web, giving them a characteristic honeycomb appearance. Hexagonal beams are the most common type, providing a balance of strength and material efficiency, and are widely used in both residential and commercial construction projects.

2. Circular (Cellular) Castellated Beams

Instead of hexagonal openings, circular castellated beams feature round holes. Known as cellular beams, they provide an aesthetically appealing alternative to hexagonal beams. They are often used in projects where the visual impact is important, while still offering the same strength and utility integration benefits.

3. Custom Castellated Beams

In some cases, castellated beams can be custom designed to include different shapes or patterns of openings, depending on the specific needs of the project. This allows for a high degree of flexibility in terms of design and load-bearing capacity.

Uses of Castellated Beams

1. Commercial and Industrial Buildings

Castellated beams are widely used in commercial and industrial buildings for structural framing. Their ability to handle long spans with minimal support makes them ideal for large open spaces such as warehouses, factories, and office buildings. The openings also make it easier to run electrical conduits, HVAC systems, and plumbing through the structures.

2. Residential Loft Conversions and Extensions

In residential construction, this type of beams is a popular choice for loft conversions and home extensions. They provide the necessary structural support without adding excessive weight to the existing building. The openings in the beams also allow for easier integration of utilities, making them an efficient option for modern homes.

3. Architectural Features

Due to their unique design, castellated beams are often used as architectural features in buildings. Exposing these beams in modern interiors adds an industrial aesthetic to the space, making them a popular choice for architects looking to combine function with style.

4. Bridges and Long Span Structures

For large-scale projects like bridges or long-span structures, castellated beams provide the necessary strength while minimising the weight of the overall structure. Their ability to span long distances with fewer support columns makes them a practical choice for such projects.

In summary, castellated beams are a versatile and efficient solution for modern construction projects. Offering a combination of strength, weight reduction, and utility integration, they are ideal for both commercial and residential applications. At MAH Steel, we specialise in fabricating castellated beams for a variety of projects, ensuring that every steel beam meets the specific requirements of your design while delivering optimal performance.