NASA Mobile Launcher Modification

ABOUT THIS PROJECT

NASA determined that modifying the ARES I mobile launcher to accommodate the heavier weight and thrust of the Space Launch System (SLS) was not only feasible but more cost effective. Various stages of operation were required to demolish existing structural framing members for reuse and installing new structural framing. The end result is an increased exhaust hole of approximately 260% to accommodate the new vehicle program.

The Ruby+Associates team helped Midwest Steel develop an Engineered Deconstruction and Erection Plan that defined each critical sequential step in the process so the structural integrity of the existing mobile launcher and the 380’ high tower would not be compromised. Worst-case forces in existing members, new members and connection were necessary to adhere to tolerances within a quarter inch.

Three major girders and two major trusses were replaced with five new girders in the new configuration. The girders were 25’ deep and range in length from 90’-133’ long. The pick weights were up to 278,000 pounds.

To add another dimension of risk to this complex project, a hurricane contingency plan was necessary due to its coastal location. The original plan required foundations, ballasts, and uplift clamps. After careful completion of the calculations the Ruby+Associates team confirmed that placing one truss back into the existing structure eliminated the need for the extra effort and additional cost.