Futuristic cityscape featuring buildings made of corrugated steel, symbolizing innovation and resilience in architecture.

The Surprising Strength of Corrugated Steel: How Geometry is Revolutionizing Construction

Lena Voss in Tech & Innovation August 2025 • 4 min read.

"Uncover how engineers are using corrugated designs to build stronger, lighter, and more efficient structures, transforming everything from bridges to buildings."

For years, the concept of using corrugated walls in construction beams was more theoretical than practical. While these designs existed, their application was limited. However, defining the intense deformed condition of a beam with a corrugated wall has become increasingly relevant as engineers seek innovative solutions for stronger, lighter, and more efficient structures. This exploration into corrugated steel beams marks a significant shift in construction mechanics.

The corrugated beam, characterized by its unique cross-section, introduces parameters like corrugation height and shape, influencing its structural behavior. Understanding these parameters is crucial for optimizing the beam's performance. Relative parameters, such as the ratio of corrugation height to width, play a vital role in determining the beam's tension distribution and overall strength.

Recent research has focused on assessing the nature of tension distribution within the cross-section of beams with varying corrugation heights. By examining different corrugation shapes, engineers aim to unlock the full potential of these innovative structural elements. This deeper understanding promises to revolutionize how we approach construction, paving the way for more resilient and sustainable designs.

The Science Behind the Strength

Futuristic cityscape featuring buildings made of corrugated steel, symbolizing innovation and resilience in architecture.

The research team employed numerical experiments using the finite element method (FEM) to simulate and analyze the behavior of corrugated beams. This approach allowed them to estimate the influence of various corrugation parameters on the beam's structural integrity. By keeping key parameters such as cross-section sizes, material properties, and loading conditions constant, they could isolate the impact of corrugation geometry.

While there are numerous possible corrugation geometries, the study focused on three common shapes: wavy (sinusoidal), broken (triangular), and trapezoidal. These shapes represent the most widely used configurations in practice. Calculations were performed on beams subjected to uniform loading, with variations in the size and relative parameter (the ratio of corrugation height to width) carefully considered.

Key factors considered in the experiments:

Cross-section dimensions
Material characteristics
Loading conditions
Fixing conditions of the beams

The "Lira" application complex was utilized for these calculations, with the "Gofro" and "GMSH" applications facilitating the creation of settlement models. "Gofro," developed by the authors, is specifically designed for describing the geometry of beams with corrugated walls, while "GMSH" generates the finite element mesh. This combination of tools allowed for accurate and detailed simulations of the beams' structural behavior.

The Future of Construction is Corrugated

The research findings indicate that the geometrical form of the corrugation has minimal impact on the nature of tension distribution within the beam section. Instead, tension distribution is primarily influenced by the ratio of corrugation height to width. When this ratio is low, the corrugated wall fully engages in the load-bearing process. As the ratio increases, only a portion of the wall contributes, eventually limited to the areas near the beam's edges. This insight is crucial for optimizing corrugated beam designs for specific applications.

About this Article -

This article was crafted using a human-AI hybrid and collaborative approach. AI assisted our team with initial drafting, research insights, identifying key questions, and image generation. Our human editors guided topic selection, defined the angle, structured the content, ensured factual accuracy and relevance, refined the tone, and conducted thorough editing to deliver helpful, high-quality information.See our About page for more information.

This article is based on research published under:

DOI-LINK: 10.4028/www.scientific.net/msf.931.247, Alternate LINK

Title: Influence Of A Metal Beam Of A Corrugated Wall Geometrical Parameters On Size And Nature Of Internal Tension Distribution

Subject: Mechanical Engineering

Journal: Materials Science Forum

Publisher: Trans Tech Publications, Ltd.

Authors: Aleksey O. Lukin, Vadim Y. Alpatov

Published: 2018-09-01

Everything You Need To Know

How do corrugated steel beams achieve their strength compared to beams constructed with other traditional materials?

Corrugated steel beams offer significant advantages due to their geometry. The corrugation introduces specific parameters, such as corrugation height and shape, that directly influence the beam's structural behavior. Engineers optimize the beam's performance by carefully managing these parameters. The ratio of corrugation height to width plays a vital role in determining the beam's tension distribution and overall strength, which is different from traditional beam designs.

What methods were employed to analyze the behavior of corrugated beams, and how did these methods help isolate the impact of corrugation geometry?

The research used the finite element method (FEM) for numerical experiments to simulate how corrugated beams behave under different conditions. The "Lira" application complex, along with "Gofro" (for defining beam geometry) and "GMSH" (for generating finite element mesh), allowed researchers to keep cross-section sizes, material properties, and loading conditions constant while varying the corrugation geometry. This enabled accurate assessment of the impact of corrugation parameters on structural integrity.

What specific corrugation shapes were examined, and are there other geometries that could potentially enhance structural performance?

The study focused on three common corrugation shapes: wavy (sinusoidal), broken (triangular), and trapezoidal, representing the most widely used configurations in construction. Although many geometries are possible, these shapes were chosen to examine the effects of varying the size and relative parameter (ratio of corrugation height to width) on the beam's structural integrity under uniform loading. Other shapes could be explored, but these provide a solid foundation for understanding the impact of geometry.

What is the most critical factor influencing tension distribution within a corrugated beam, and how does it affect load-bearing capacity?

Tension distribution within a corrugated beam is most affected by the ratio of corrugation height to width, not the specific geometrical form of the corrugation (wavy, broken, or trapezoidal). When the ratio is low, the entire corrugated wall bears the load. As the ratio increases, only the areas near the beam's edges contribute. This understanding is crucial for optimizing the design of corrugated beams for specific applications, balancing material use and structural performance.

Beyond the corrugation's shape and height-to-width ratio, what other parameters might influence the structural capabilities of corrugated steel beams?

While tension distribution relies on the ratio of corrugation height to width, other factors could influence the structural behavior of corrugated steel beams. Material properties such as yield strength and elasticity, and fixing conditions of the beams at their supports also play a significant role. Future studies could investigate how these factors interact with corrugation geometry to further optimize corrugated beam design and applications.