Conventional building materials encounter challenges, such as high self-weight, poor corrosion, poor fireproofing, poor waterproofing, poor moisture-proofing, and high maintenance costs. Nowadays, more and more researchers are committed to investigating innovative new material substitutes. Thus, extensive research on CSIPs has been conducted at the University of Alabama at Birmingham. Professor Uddin’s research team presented composite structural insulated panels (CSIPs). The designs for the section of the CSIPs were proposed by Vaidva et al. [
1]. (
Figure 1), such as the thickness of the glass–polypropylene (PP) face sheets (3.04 mm) and EPS core (140 mm). The face sheets of CSIPs exhibit high impact-resistance and strength, good waterproofing, moisture-proofing, fire-proofing, anti-corrosion, and eco-friendly characteristics, whereas the EPS middle sheets bear the shearing stress, and two outer PP faces resist buckling and improve its stiffness. Thus, as the structural layout of CSIPs, the use of glass–polypropylene (PP) sheets is appropriate because it provides a high ratio of strength to weight, fine impact resistance, and good durability. Meanwhile, EPS foam is so light weight that it is used for the CSIP core. Thus, it has an excellent performance in things such as heat insulation, excellent impact-resistance, anti-bending, fire-proofing, and keeping warm [
1]. Therefore, it is important that CSIPs’ mechanical properties are studied.
In recent years, considerable research has been devoted to developing sandwich composite materials. Wang et al. discussed the shearing of beams and panels with higher order hypotheses [
2]. Liu et al. proposed layer-wise shear deformation theory of composite laminated plates by DQFEM [
3]. Pawlus solved the stability of asymmetrical three-layered annular plates under loads in a plane [
4]. The influence of a thin middle sheet of bending on the sandwich beams was presented the by Iaccarino et al. [
5]. Grygorowicz and Lewiński presented a three-point bending of an I-beam considering the transverse shear effect [
6]. Under the higher-order zigzag principle, static FE analyses of sandwich beams in both outer sheets and soft cores were presented by Chakrabarti et al. [
7]. Wittenbeck et al. studied the three-point bending of sandwich beams with corrugated cores [
8]. Roque et al. presented the bending of simply supported laminated composite beams subjected to transverse loads by a modified couple stress theory and a meshless method [
9]. Batra and Xiao gave finite transient deformations of a curved laminated beam composed of a St. Venant–Kirchhoff material [
10]. De Santis et al. obtained the behavior effects of composite glulam beams with circular holes [
11]. Rocha et al. presented the structural concept of post-tensioned Fe-SMAs glass systems [
12]. Bui et al. investigated transient responses and natural frequencies of sandwich beams with inhomogeneous functionally graded (FG) cores [
13]. Marczak and Jędrysiak built a model of sandwich structures with inert cores [
14,
15]. Matuszewska and Strek studied a vibration analysis of a beam by an auxetic cross-section [
16]. Grygorowicz and Magucka-Blandzi gave static and dynamic stabilities of a simply supported three-layered beam with a metal foam core [
17]. Jopek and Strek presented the torsion of a two-phased composite bar with helical distribution of constituents by the FEM method [
18]. Teter showed that simply supported columns are subjected to in-plane pulse loading at the loaded end by the analytical–numerical method (ANM), using Koiter’s perturbations method [
19]. The study of the failure mechanisms of sandwich beams with horizontal loads was performed by Steeves et al. and Qin et al. [
20,
21]. Tian et al. proposed the instability of structural members under axial compression causes [
22] The bending problems of sandwich beams made of a metal foam core were presented by Magnucka-Blandzi et al. [
23,
24]. The connections between foam sheets was gained considering cracks in the connections of the fibers and foam sheets by Zenkert. [
25]. The effect of the fiber transverse dimension of the binding layer under the deformation of beam bending was presented by Magnucki et al. [
26]. Mori et al. gained insight into the mechanisms of deformation and the mechanics of sandwich structures subjected to underwater shock loading [
27]. A formal engineering method of the mechanics of thin-walled laminated beams was obtained under kinematic assumptions by Barbero et al.; it has a good agreement with Timoshenko’s beam theory [
28]. Yuan et al. proposed the bending influence of shear deflection on laminated sandwich box cantilever beams [
29]. Pawar demonstrated that the thin-walled composite box beams by 3D Finite Element Modeling were a feasible solution [
30].
Uddin et al. investigated the behavior of the whole bending of CSIP wall panels (CSIPs) under concentric and eccentric load in a plane [
31,
32]. Du and Uddin presented concepts of the new CSIP thin-walled laminated shell, which it is different from the traditional concrete thin shell [
33]. Due to the advantages of CSIP plates and shells, such as a high strength–weight ratio, excellent impact resistance, and high durableness, they are used as enclosure members in civil engineering. However, previous research did not focus on the stress, strain, and deflection in each laminated layer of the sandwich plates and beams.
With an excellent strength–weight ratio and good anti-impact properties, civil engineering will apply CSIPs to load-bearing structures. The stiffness of CSIPs is so small that the load-bearing members made of CSIP composite materials have a great challenge, which is the large deflection. Consequently, focusing research on enhancing CSIPs’ stiffness is essential. In the present study, the new innovative CSIPs improved the stiffness of the materials, which are made of E-glass (PP) layers as the surface, and a polystyrene (EPS) foam core. Innovative CSIPs are derived from sandwich panels, which have a foam core with a thickness of 120 mm and a surface with thickness of 9 mm. On the other hand, the box-beams are used because of their excellent mechanical properties—a larger rigidity and strong torsion resistance. These innovations can be developed to enhance efficiency through special designs. In this study, stress, strain, and deflection of each of the face sheets of the CSIP thin-wall box-beam will be carried out by theoretical analysis. The FE model of the CSIP thin-wall box-beam was constructed using the ANSYS Workbench. Finally, by comparing the theoretical results with the FE results, the feasibility of the theoretical model is evaluated.