What is a good way to make a cardboard castle entrance for a hallway more sturdy?

Question

Every year at my school we have this tradition where we decorate hallways. Each class is assigned a hallway. This year our hallway theme is a haunted castle and I am designing a castle entrance. I was wondering if anyone knew how to make the cardboard entrance more sturdy.

Answer 1

A couple of things to keep in mind when working with corrugated board.

The strength of the material is greatest along the flutes.

If you take a square of material one direction will fold easier than the other.  It can be scored with a screen roller (tool for putting screen in windows.) or the back of a box knife with the blade retracted so only using the metal of the case.

You can control fold by scoring the material.  Scoring is crushing the material in a line that will be the path for the material to bend.

Strength can be added by adding scores and panels going in the direction you want to enforce.  For example you can add a couple panels that would roll up and make a beam.

If needed you can create beams by scoring board to to make like a paper 2 x 4 log.

Corrugated comes in different board grades.  The heaver grades being stronger.

When you paint, the moisture will weaken the material.  Some strength will come back as the paint dries.