Comparative Study on Weight Efficiency of Castellated Steel Beams and Conventional I-Beams

In modern steel construction, reducing self-weight while maintaining structural adequacy is a key design objective. Castellated steel beams, fabricated by introducing web openings into rolled I-sections, are widely recognized for their enhanced depth and improved structural efficiency. This study presents a comparative investigation on the weight efficiency of castellated steel beams versus conventional rolled steel beams designed for identical loading and span conditions. Beams with spans of 10 m, 13 m, and 16 m are designed in accordance with IS 800:2007 provisions. Finite Element Analysis (FEA) is carried out using ANSYS to validate structural performance in terms of stress and deflection. The results highlight that castellated beams achieve significant weight reduction—up to 20–25%—without compromising serviceability or strength requirements. The study establishes castellated beams as a structurally efficient and economical alternative to conventional steel beams in long-span applications.

Castellated beams, Weight optimization, Material efficiency, Steel structures

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