Stronger structures experiment
Corrugating card structures and testing them to failure
Children often learn best when they can interact directly with their learning materials. Building card models and testing their strength allows for tactile learning, while teaching them about structural integrity.
This is one of a set of resources developed to support the teaching of the primary national curriculum, particularly key stage two (KS2). It has been designed to support the delivery of key topics within science, maths and design and technology (DT). This experiment focusses on testing how well different shaped structures perform under load.
This could be used as a one-off activity or as part of a wider unit of work focussing on structures and structural systems. It could also be used as a maths activity focussing on 3D shapes and the presentation of data.
Activity: Corrugating card structures and testing them to failure
In this STEM experiment, learners will construct card models of a cuboid, a triangular prism, and a cylinder. They will then test each structure's strength under load, record their results, and discover ways to reinforce these structures for increased strength. This hands-on experience not only makes learning fun but also provides practical knowledge about 3D shapes and data presentation.
Tools/supplies needed:
- 210 mm x 210 mm thin card
- Scissors
- Masking tape
Follow our step-by-step guide on corrugating card structures and testing them to failure
How to make a cuboid
1. Make four equally spaced fold lines on a square piece of card.
2. Fold inwards along each line to form a hollow cuboid.
3. Stick a piece of masking tape along the full length of the point where the end card pieces meet, to join them.
How to make a prism
1. Make three equally spaced fold lines on a square piece of card.
2. Fold inwards along each line to form a hollow triangular prism.
3. Stick a piece of masking tape along the full length of the point where the end card pieces meet, to join them.
How to make a cylinder
1. Fold a square piece of card inwards to form a hollow cylinder.
2. Stick a piece of masking tape along the full length of the point where the end card pieces meet, to join them.
Load testing each structure
For each shaped structure that you have built:
1. Place books on top of the structure, one at a time.
2. Write down how many books can sit on top of the structure before it fails.
3. Which is the strongest and which is the weakest structure?
Reinforcing each structure
1. Cut 210 mm long strips of card that would fit exactly through the centre of each shape.
2. Place the strips of card through the centre of each shape and tape in place.
3. Repeat the load testing. What difference does this reinforcing make?
4. Add further reinforcement and test its effect.
The engineering context
This activity provides a glimpse into the world of engineering. Engineers need to understand how structural systems work, how they are tested, and how they can be reinforced. This knowledge is essential when constructing and testing their own structural systems, such as bridges, buildings, or boat/aircraft hulls.
Suggested learning outcomes
Through this activity, learners will enhance their skills in several areas. They will learn to construct models of a cuboid, a triangular prism, and a cylinder. They will understand how different shaped structures perform under load and discover ways to strengthen and reinforce these structures. This activity can be used as a standalone lesson or as part of a wider unit focusing on structures and structural systems.
Download our activity sheet and other teaching resources
All activity worksheets and supporting resources are free to download, and all the documents are fully editable, so you can tailor them to your students’ and your schools’ needs.
The activity sheet includes teachers’ notes, useful web links, and links (where appropriate) to the national curriculum in each of the four devolved nations; England, Northern Ireland, Scotland and Wales.
You can download our step-by-step instructions below as either a classroom lesson plan or PowerPoint presentation.
And please do share your classroom learning highlights with us @IETeducation.
