Objectives: The primary objective of this current research is to determine the ideal horizontal spacing for hexagonal web openings and their maximum load-bearing capacity through Finite Element Analysis (FEA). Methods: The ISMB150 was implemented as a cross-sectional profile to fabricate distinct models of castellated beams with heights of 225 mm. The height of the web openings remained constant at 150 mm for the castellated beam model. The entire analysis is being done on ANSYS 19.2. Findings: The analysis has revealed that, for castellated beams with shallower depths, an optimal horizontal spacing of 44.9 mm for the web openings yields an ultimate load-bearing capacity of 144.26 KN. The results of castellated beams are measured in terms of ultimate load-carrying capacity, span-to-deflection ratio, load density, failure location, span-to-beam depth ratio, and the ratio of horizontal distance of opening-to-opening depth. Novelty: This research contributes analytical findings for the ideal horizontal distance of hexagonal web opening through maximum load-bearing capacity. Castellated beams have gained immense popularity within the structural engineering community today due to their visually appealing design featuring a variety of web-opening shapes. The primary objective of this current research is to determine the ideal horizontal spacing for hexagonal web openings and their maximum load-bearing capacity through Finite Element Analysis (FEA). The ISMB150 was implemented as a cross-sectional profile to fabricate distinct models of castellated beams with heights of 225 mm. The height of the web openings remained constant at 150 mm for the castellated beam model. The analysis has revealed that, for castellated beams with shallower depths, an optimal horizontal spacing of 44.9 mm for the web openings yields an ultimate load-bearing capacity of 144.26 KN. The results of castellated beams are measured in terms of ultimate load-carrying capacity, span-to-deflection ratio, load density, failure location, span-to-beam depth ratio, and the ratio of horizontal distance of opening-to-opening depth. This research contributes valuable insights into optimizing the design of castellated beams for enhanced structural performance. Further exploration and validation could provide additional refinements and applications in structural engineering. Keywords: Horizontal distance of web opening, Number of openings, Ultimate load carrying capacity, Failure modes, ANSYS, Castellated beams
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