VICKSBURG, Miss.— When a single metal pin broke inside a navigation lock on the Ouachita River, the lock went out of service, temporarily halting river traffic and creating the need for an urgent fix.
Enter the U.S. Army Engineer Research and Development Center (ERDC) Fabrication Shops, a group of highly skilled craftsmen who build custom products that help accomplish the mission of the U.S. Army Corps of Engineers (USACE). In just a few short days and using a 60-year-old drawing, the team redesigned and fabricated a custom pin — at half the cost and faster than a 12-week commercial quote — reopening the lock and restoring river traffic in just two days.
ERDC’s Fabrication Shops serve as a unique capability within USACE, providing the Corps with the ability to quickly design, build or repair specialized mechanisms needed to accomplish the mission. Comprised of the Machine Shop, Model Shop and Welding Shop, the team of nearly 30 craftsmen works closely with engineers and project teams to fabricate everything from hydraulic models to field repairs.
But the shops don’t just make parts for emergency repair, they’re also embedded in research projects at ERDC.
“The things we make can’t be bought on a shelf anywhere,” explained Zach Smith, program manager for the ERDC Fabrication Shops. “We are a one-stop shop that can make highly unique items you can’t find anywhere else.”
The shops are home to machinists, welders, carpenters, pipefitters, masons, model makers and more. Together, the staff has decades of experience, and each person is often skilled in more than one trade.
“The people who work here make it so unique,” Smith said. “They’re all great problem solvers. The researchers come to us to make it happen, and we help their ideas come to life.”
Smith said that most projects begin with a concept, sketch or technical drawing — sometimes even on the back of a napkin. From there, craftsmen work alongside the researchers to determine the best materials, fabrication techniques and design adjustments needed to turn the idea into a working component that can be tested.
“The craftsmen’s ability to move quickly and build highly specialized pieces is a major advantage for researchers,” Smith explained. “Many of our craftsmen have spent years working in fabrication and research environments, so they understand how experiments work and how to build components that meet those requirements.”
Gary Bell, a research civil engineer with ERDC’s Coastal and Hydraulics Laboratory, said his work with physical modeling wouldn’t be possible without the Fabrication Shops.
“They are the backbone in enabling our team to successfully execute very complex model studies that require a high degree of precision,” Bell explained. “With changes that occur within a project’s lifespan, ERDC is able to be flexible and adapt those needs throughout a research effort and give our sponsors/collaborators the best possible product.”
From precision machined components to large structural test frames and detailed hydraulic models of locks, dams and coastal systems, the shops provide the physical tools researchers need to test new ideas before they are implemented in the real world. That same problem-solving mindset also allows the team to respond quickly when unexpected challenges arise, like the broken lock pin on the Ouachita River. Behind the scenes, their work helps turn ideas into solutions that address some of the nation’s toughest engineering challenges.