Accurate predictions of the drag penalty in rough-wall flows require careful characterisation of surface roughness to determine the equivalent sand-grain roughness height (k_s). The procedure involves measuring wall-shear stress (τ_w) using direct or indirect methods and analyzing velocity profiles. However, indirect methods often rely on assumptions whose validity cannot always be guaranteed. In this paper (partly based on the study [1]), wind tunnel measurements on a realistic rough surface scanned from a fouled ship hull are carried out to evaluate drag penalty predictions. Current data enabled the evaluation of k_s and associated wake parameters using several methods, which were then used for full-scale drag penalty predictions at high Reynolds numbers, with results showing the drag penalty could vary by nearly 15% among methods, highlighting the importance of exercising caution when employing such methods.

The floating-element (FE) principle, introduced nearly a century ago, remains one of the most versatile direct wall shear stress measurement methods. Yet, its intrinsic sources of systematic error, associated with the flow-exposed gap, off-axis load sensitivity, and calibration, have thus far limited its widespread application. In combination with the lack of standard designs and testing procedures, measurement reliability still hinges heavily on individual judgement and expertise. This paper presents a framework to curb these limitations, whereby the design and operation of a FE balance are leveraged by an analytical model that attempts to capture the behaviour and predict the relative contribution of the systematic sources of error. The design is based on a parallel-shift linkage and a zero-displacement force-feedback system. The FE has a surface area of 200×200 mm, and measurement sensitivity is adjustable depending on the surface condition and the Reynolds number. It is thus suitable for application in a wide range of low-speed, boundary-layer wind tunnels, small or large scale. Measurements of the skin friction coefficient over a smooth wall show a remarkable agreement with oil-film interferometry, especially for Re_θ>1.3×10⁴. The discrepancy relative to the empirical Coles–Fernholz relation (κ=0.39 and C=4.352) is within 0.5%, and the level of uncertainty is below 1% for a confidence interval of 95%.

Full-scale drag penalty predictions of flows over rough walls require surface roughness characterisation from laboratory experiments or numerical simulations. In either approach, it is necessary to determine the so-called equivalent sand-grain roughness height (k_s ). There are several steps involved in determining this aerodynamic roughness lengthscale, but its procedure typically includes a combination of measurement of wall-shear stress (τ_w ) using direct or indirect methods as well as analysis of velocity profiles. Indirect methods usually rely on assumptions made about flow and its scaling including the validity of universal outer-layer similarity. However, the implications of the underlying assumptions involved in full-scale drag prediction are unclear. In this work, we carry out wind tunnel measurements over a realistic rough surface (from a fouled ship-hull) to evaluate the impact of different methods with an emphasis on using the outer-layer similarity hypothesis for full-scale drag predictions. Wall-shear stress is measured using an in-house floating-element drag balance (DB), and velocity profiles are obtained using particle image velocimetry (PIV), allowing the evaluation of k_s , and the associated wake parameters through several methods. The aerodynamic roughness parameters hence obtained are used for full-scale drag penalty calculations. It is observed that the predicted drag penalty can vary by over 15 % among the different methods highlighting the care that should be taken when employing such methods.