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

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.
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.
Because the beams span farther and are lighter for their strength, installation is fast and efficient—with easier handling and fewer interruptions onsite.
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.
Design flexibility supports future upgrades like rooftop solar or HVAC changes without major structural modifications—helping buildings adapt over time.
The open-web profile can enhance architectural appearance and allow natural light through the structure.
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

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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.