castellated beams
Build faster. Save more. Build greener.
Next Level Steel’s castellated beam systems deliver longer spans, faster erection, and smarter building performance for industrial and commercial projects nationwide. Castellated beams are created by precision-cutting and welding traditional steel I-beams into a staggered pattern with distinctive hexagonal openings—boosting depth and strength while reducing weight.
Expanding Possibility, One Beam at a Time
Innovation: First office campus to showcase Next Level Steel’s proprietary Castellated Beams.
Benefits: Longer spans, future-proof load capacity, integrated utility access.
Collaboration: Thanks to Wespac Construction, PK Associates, and Trammell Crow Company.
Information
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Castellated beams are engineered to do more with less material. The open-web “castle” pattern increases beam depth and structural efficiency without adding steel — making them a powerful, lightweight solution for modern construction.
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Our castellated beams are taller and stronger than standard I-beams, supporting heavier loads and spanning longer distances—ideal for large rooftops and open floor plans.
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Because the beams span farther and are lighter for their strength, installation is fast and efficient—with easier handling and fewer interruptions onsite.
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The web openings make routing HVAC, plumbing, and electrical simpler—often reducing the need for additional penetrations and helping lower floor-to-floor height compared to joists spanning the same distance.
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Design flexibility supports future upgrades like rooftop solar or HVAC changes without major structural modifications—helping buildings adapt over time.
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The open-web profile can enhance architectural appearance and allow natural light through the structure.
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Castellated beams deliver higher moment-carrying capacity with no added steel, plus a high stiffness-to-weight ratio that can help minimize floor vibration issues.
Benefits of Castellated Beams
Performance Snapshot
Span capability:
beams can be extended up to 100+ ft.
Depth capability:
depth can be increased up to 66 in.
Sustainability note:
up to 40% more moment-carrying capacity using no extra steel, supporting a lower material footprint.
case study
Sprouts HQ & Campus - Phoenix, AZ
Big things are going up at CityNorth! We’re proud to supply the structural steel solutions that will bring the new Sprouts Farmers Market headquarters and campus to life.
This project marks the first commercial application of our eco-friendly, super-spanning Castellated Beams in a major office building — a proof point that these innovative components go beyond industrial use to deliver strength + style in corporate environments.
Project Highlights:
4-story, 144,500 sq. ft. corporate HQ
25,000 sq. ft. Sprouts grocery store
11,000 sq. ft. restaurant + retail space
3-story parking garage
Future amenities:
gym, yoga studio, tasting rooms & more
Partners:
General Contractor: Wespac Construction
Structural Engineering: PK Associates
Developer: Trammell Crow Company
At the core of it all: Next Level Steel Castellated Beams, delivering span efficiency, architectural flair, and sustainability.
Ready to elevate your next project?
Request technical specs, product guidance, or a quote for your castellated beam package.