About the Project
The $190 million modification project transforms a historic launch complex into the only dual-use pad in the world that handles both Atlas V and Vulcan Centaur rockets simultaneously. The project consists of a new 183-foot-tall Vulcan Launch Platform (VLP). It is outfitted with the equipment and umbilicals needed to supply the Vulcan Centaur with liquid natural gas (LNG) propellant and liquid oxygen to the first stage, liquid oxygen and liquid hydrogen to the Centaur upper stage, conditioned air to customer spacecraft and rocket compartments, electronics, power lines and command-and-control cabling.
Modifications to the active launch pad’s infrastructure include the installation of a 100,000-gallon LNG storage area, a 122,000-gallon Centaur liquid hydrogen (LH2) area and a 65,000-gallon liquid oxygen (BLOX/CLOX) storage area, and an improved Acoustic Suppression Water System (ASWS) with 28-inch pipes and additional larger water tanks.
Work also included modifications to the Vehicle Integration Facility (VIF) platforms to accommodate the 12-foot-diameter Atlas V with up to five Solid Rocket Boosters (SRBs) and the 18-foot-diameter Vulcan Centaur rockets with up to six SRBs. Modifications to the Spaceflight Processing Operations Center (SPOC) included a new 160-foot tower and access platforms and the scope for Service Vans (M-Van, P-Van & S-Van) consisted of miles of control cabling and reconfiguration of thousands of termination points to allow control and monitoring of the payload.
“Hensel Phelps is an essential partner in placing the United States’ strategic assets for the defense of our country.”
Eric Richards, Program Manager, Vulcan Centaur Infrastructure Activations
Challenge
Working on an Active Launch Pad
Launch Complex 41 is an active launch pad with scheduled launch windows. Operations could not be interrupted by construction, so Hensel Phelps was required to perform work within work windows ranging from 30 days to three months.
Solution
Collaboration and Offsite Prefabrication
Hensel Phelps, ULA and other stakeholders relied heavily on scheduling tools to perform work within the required windows. Before each work window, Hensel Phelps would host a go/no-go meeting with ULA, trade partners and vendors to ensure confidence that work can be completed within the time allotted. Hensel Phelps also received the updated launch manifest periodically. While a launch was occurring, Hensel Phelps temporarily moved into the SPOC and continued scopes of work for those areas since it was far enough from the pad to be considered a safe work zone.
In addition, Hensel Phelps relied upon offsite prefabrication and virtual design and construction (VDC) coordination for connection points, alignment and surveying. The Vulcan Launch Platform was designed and built offsite, so there was no interruption of work or launches. Assembling offsite also enhanced the ability to control quality and safety and allowed many construction activities to happen in a controlled environment. Once completed, the pieces were brought to the SPOC for final assembly. This was accomplished by closing multiple roads, a police escort and a very large vehicle (i.e. K-Mag) to transport the VLP sections over several occurrences. This process played out over additional scopes of work, such as access platforms in the SPOC, VIF, and Acoustic Water Suppression System lower ring. Coordinating with the city, local police station, Cape Canaveral Space Force Station and Hensel Phelps was achieved without any complications.
Result
Maintaining an Active Launch Pad
By closely collaborating and maximizing offsite prefabrication opportunities, 16 launches went off without a hitch, ensuring that over $3.6 billion in launch costs from Launch Complex 41 were not compromised.
Awards
2023
Associated General Contractors (AGC) of America, Build America Award of Merit – Construction Management New or Renovation ($100M or more)
2022
Associated Builders and Contractors (ABC) Central Florida, Excellence in Construction (EIC) Eagle Award – Industrial ($100-$250M)
Engineering News-Record (ENR), Best Project – Specialty Construction
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