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@article{207578,
        author = {Suraj Potdar and Girish Joshi},
        title = {A Critical Review on Analysis and Design of Castellated Beams and Rapid Metal Development (RMD) in Modern Steel Construction},
        journal = {International Journal of Innovative Research in Technology},
        year = {2026},
        volume = {13},
        number = {3},
        pages = {1626-1633},
        issn = {2349-6002},
        url = {https://ijirt.org/article?manuscript=207578},
        abstract = {Castellated beams are widely used in steel construction because they provide higher flexural stiffness and longer-span capability by increasing the effective depth of rolled sections without a proportional increase in self-weight. However, the introduction of regular web openings also changes the internal force path and creates local effects such as Vierendeel bending, web-post buckling, stress concentration, weld rupture, serviceability deflection, and lateral-torsional buckling. Rapid Metal Development (RMD), represented by CNC cutting, automated fitting, robotic welding, digital detailing, and quality-controlled prefabrication, has the potential to improve the dimensional accuracy and repeatability of castellated beam fabrication. This review paper synthesizes research on the behaviour, design, numerical modelling, failure mechanisms, opening-shape optimization, and fabrication requirements of castellated and cellular beams. The review shows that circular and sinusoidal openings generally reduce sharp-corner stress concentration, whereas hexagonal openings remain economical but require careful checks for web-post stability and Vierendeel action. Literature further indicates that numerical finite element models can predict key response parameters effectively when validated against experiments. A major research gap remains in the integrated evaluation of castellated beam performance with RMD-based fabrication tolerances, residual stresses, automated weld quality, fatigue, fire response, and code calibration for Indian construction practice. The paper concludes with research directions for AI-assisted opening optimization, experimental validation of RMD-fabricated beams, codal design development, and sustainability-oriented steel construction.},
        keywords = {Castellated beam; cellular beam; Rapid Metal Development; web opening; Vierendeel mechanism; web-post buckling; finite element analysis; steel construction; robotic welding; CNC cutting.},
        month = {August},
        }