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Castellated Beams - Definition and Fabrication Process A castellated beam is a structural steel member derived from a standard rolled I-section by cutting the web along a predetermined zigzag (hexagonal) pattern using thermal or mechanical cutting. The two halves are then longitudinally offset and reconnected by full-penetration welding, resulting in an increased overall depth while maintaining nearly the same cross-sectional area. The cutting pattern typically produces hexagonal web openings, w
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