Castellated beams, recognized for their favorable strength-to-weight ratio and ease of utility passage, are widely used. Despite extensive studies focusing on their flexural performance, a significant research gap remains regarding the effects of corrosion, particularly in terms of web-post buckling (WPB). There are no experiments reported or formulations to predict the buckling of corroded webs. To address this gap, four full-scale beams, comprising two corroded and two non-corroded specimens of ASTM A572 Grade 50 and Grade 60 steels, were tested under three-point bending. The influence of corrosion on buckling was assessed using digital image correlation (DIC) in conjunction with pit morphology analysis and mass loss measurements. Additionally, a new rational formulation was proposed incorporating periodic thickness variation to account for corrosion pits. Experimental results indicated substantial reductions in load-bearing capacity due to corrosion, approximately 39 % for Grade 50 and 36 % for Grade 60. The analytical model demonstrated high accuracy for the present tests, with mean deviations of about 8.5 % and 2.9 % for the non-corroded Grade 50 and Grade 60 beams and about 1.7 % for the corroded specimens. When applied to additional non-corroded beams from the literature, the model showed mean deviations of about 7 %. For the non-corroded case, existing design provisions produced less accurate predictions: EN 1993–1–13:2024 underestimated the experimental results by an average of 40.8 %, whereas Steel Design Guide 31 overestimated the critical shear load by an average of 17.4%. The findings underscore the importance of considering corrosion-induced slenderness to predict structural stability and durability of castellated beams.
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