Schebler Specialty Fab Helps University of Iowa Make Waves

Schebler Specialty Fab was given an important college assignment: fabricate a complex, moving truss bridge from 1,250 feet of aluminum tubing, precision-cut, formed and welded.

The structure was designed for a $4.9 million first-of-its-kind Wave Basin Laboratory funded by the U.S. Navy, and installed at the University of Iowa’s Institute of Hydraulic Research. UI engineering staff is able to simulate stormy sea conditions—from pitch and roll to slamming and ship-to-ship interaction—and measure the effects on radio-controlled, scale model vessels. The 70’ truss bridge spans the wave pool as part of an automated gantry carrying cameras and computers.

The truss was bolted onto two trucks located on both sides of the test basin containing six wave-makers. The gantry moves quickly and accurately to shadow the vessels within +/- 100 mm. The truss not only needed to support the measurement tolerances and fit the footprint of the gantry, but the hole patterns needed to be a perfect match, making the dimensional accuracy of the truss critical. The overhead carriage tracks the radio-controlled ships using indoor global positioning and two-camera vision. A 3D particle image velocimetry system measures fluid velocities around the ships, facilitating the collection of detailed flow data. The scale models are tested for maneuvering, sea-keeping, etc. — potentially saving lives when the ship design is in use by the U.S. Navy.

Besides the ability to perform the job as a single-source supplier, Schebler was selected for the demanding project based on several critical factors. Among these were the capability and reputation for fabricating and welding complex aluminum assemblies, precision forming, holding tight tolerances and laser cutting.

Once welded, assembled and the final inspection on the shop floor, the truss bridge was disassembled for powder-coating and traveled along Interstate 80 to Iowa City—in 20 horizontal tower and bracing segments.

Our capabilities to produce custom, complex fabrications is unparalleled. For more information on our custom fabrications, visit our website!