Overview
Our team designed and built cost-effective sheet metal breakers to stabilise pontoons carrying sensitive equipment. The breakers reduced turbulence and excessive swell, helping maintain reliable measurements. We addressed material limitations and the saline environment by using galvanised sheet metal, optimised shapes, and reinforced framing. The final design provided both durability and effective water deflection while also being practical to manufacture.

‍Methodology
We started by designing the breaker shapes to fit standard sheet sizes and optimising the layout to make the most of available materials. Our team developed strong framing to reduce movement and prevent fatigue, confirming its strength through FEA testing. We produced clear fabrication documents - including cutting, assembly, and finishing files, plus weld guides - to make manufacturing straightforward. Finally, we worked with coating specialists to apply a zinc-blasted and baked protective layer, ensuring the breakers would withstand harsh marine conditions for long term use.

‍Results Discussion
‍The sheet metal breakers successfully enhanced pontoon stability, reduced turbulence, and protected sensitive equipment. Careful material selection, efficient design within stock constraints, and structural validation through FEA were key to the project’s success. The coordinated approach to fabrication, finishing, and protective coatings ensured long-term durability and reliability in a demanding marine environment.