APPENDIX A (RFI) FOR THE FABRICATION OF MULTIPLE STEEL REACTION STRUCTURES FOR NASA-MSFC STRUCTURAL TESTING Mike Roberts 12/2/09

Large Steel Structure Procurements 28 steel structures totaling >4.5 million lb Special Test Equipment (STE or Test Fixtures) Groupings: – Group 1 - Interface Rings (8) – Group 2 - Spiders (4) – Group 3 - Pedestals (3) – Group 4 - Reaction Structure (13) 20,000 lb - 600,000 lb (most <100,000 lb) Delivery to MSFC – build up and deliver one piece – build up and teardown for delivery Schedule – Procurement Cycle starts January 2014 – All deliveries end of 2014 through middle of /20/20132APPENDIX – RFI – MSFC STEEL STRUCTURES

General Procurements Schedule – Schedule data below is for a typical item from each group (fabrication time – red bar). 12/20/20133APPENDIX – RFI – MSFC STEEL STRUCTURES

GROUP 1 – INTERFACE RINGS Qty 8 – 7 items, qty 1 of each item except qty 2 of Interface Ring #6 General design requirements for each ring: – General Design Geometry 27.5’ barrel diameter 10”-4’ Height Plate thicknesses – 1” – 4” Flanged interfaces top and bottom with multiple holes (“T” x-section; holes; 1”-3” hole D) STRESS RELIEF REQUIRED for each interface ring. – Material Steel plate per ASTM A572, Grade 50 – Tolerances Typical tolerances, except: One Flange must be machined to tight tolerances (see charts for details): – Welding CJP welds, groove welds, fillet welds (see charts for typical weld callouts) Flanges are multi-piece welded together and welded to rolled barrel/web Gussets welded to flanges/web Welds per AWS D1.1, certified inspection (mag particle/ultrasonic/visual by supplier) – Weight 30,000 lb – >200,000 lb – Transportation All interface rings are ONE PIECE delivered to MSFC 12/20/20134APPENDIX – RFI – MSFC STEEL STRUCTURES

Weight: ~210K lbs 2.5” Top Ring 1” thick plate Barrel and Gussets 4” thick plate Base 35 ft 4 ft 30 ft INTERFACE RING #1 TIGHT TOLERANCE INTERFACE – See pg. 13 for tolerances for this interface 3” D bolt holes (qty 200)

INTERFACE RING #2 12/20/20136APPENDIX – RFI – MSFC STEEL STRUCTURES 30 ft TIGHT TOLERANCE INTERFACE – See pg. 13 for tolerances for this interface.5” THK gusset 2.5” top 2.0” bottom 1.0” web W 10x49 beam Weight: ~50k lbs

Weight: ~45k lbs 36” Dia 348” 2.0” THK top and bottom 1.0” THK web 1.5” THK plate.5” THK plate INTERFACE RING #3 12/20/2013APPENDIX – RFI – MSFC STEEL STRUCTURES7

2.5” THK bottom 2.0” THK top Dia 343” W 10x49 beam.75” THK gusset 1.0” THK web.5” THK gusset 10” INTERFACE RING #4 Weight:22K lbs 12/20/2013APPENDIX – RFI – MSFC STEEL STRUCTURES8 TIGHT TOLERANCE INTERFACE – See pg. 13 for tolerances for this interface

Weight: ~23K lbs.5” THK gusset 2.5” top 2.0” bottom 1.0” web Dia 346” 13” INTERFACE RING #5 12/20/2013APPENDIX – RFI – MSFC STEEL STRUCTURES9 TIGHT TOLERANCE INTERFACE – See pg. 13 for tolerances for this interface

28” Material: ASTM A572, Grade 50 Web Diameter: 27.5’ Thickness: 1.5” Height: 23” INTERFACE RING #6 Flanges OD: 28.7’ ID: 26.3’ T: 2.5” Holes (Top): 1” holes (2 rows of 192 each) Holes (Bot): 1.5” holes (2 rows of 120 each) Inner D: 27’ Outer D: 28’ Interface Ring Gussets Dimensions: 23” X 6” X 1” 15 degrees apart (inside and out) APPENDIX – RFI – MSFC STEEL STRUCTURES12/20/ TIGHT TOLERANCE INTERFACE – See pg. 13 for tolerances for this interface Weight: ~40K lbs

INTERFACE RING #7 12/20/201311APPENDIX – RFI – MSFC STEEL STRUCTURES TIGHT TOLERANCE INTERFACE – See pg. 13 for tolerances for this interface 2.5” THK bottom 2.0” THK top Dia 343” 1.0” THK web.5” THK gusset 10” Weight: 22K lbs

Typical INTERFACE RING Weld Callouts 12/20/201312APPENDIX – RFI – MSFC STEEL STRUCTURES

13 Typical INTERFACE RING Typical INTERFACE RING Tight Tolerance Details 12/20/201313APPENDIX – RFI – MSFC STEEL STRUCTURES 0.050” flatness (+/-0.25”) over entire interface surface

GROUP 2 - SPIDERS Qty 4 – 4 items, qty 1 of each item General design requirements for each Spider: – General Design Geometry Welded wide-flange I-beams stiffened by plates Large sections (e.g. W36x441) 28’ – 44’ Diameter 3’-4’ Height Plate thicknesses – 1” – 2” STRESS RELIEF REQUIRED for each spider – Material ASTM A992 Beams Steel plate per ASTM A572, Grade 50 – Tolerances Typical tolerances for I-beam construction Some machined surfaces (see charts for details) – Welding CJP welds, groove welds, fillet welds (see charts for typical weld callouts) Gussets welded to flanges/web Welds per AWS D1.1, certified inspection (mag particle/ultrasonic/visual by supplier) – Weight 66,000 lb – 278,000 lb – Transportation 3 of 4 spiders are ONE PIECE delivered to MSFC 1 spider (Spider #4) is MULT-PIECE delivery 12/20/201314APPENDIX – RFI – MSFC STEEL STRUCTURES

Spider #1 Beams – W36X330 One piece – all welded Weight – 180,000 lb Machined interface plate at 27.5’ D 3.2’ 35’ 27.5’ 17’ APPENDIX – RFI – MSFC STEEL STRUCTURES 12/20/201315

Spider #1 Top Level Assembly Sub-Assembly 4X 1X 4X Sub-Assembly 8X APPENDIX – RFI – MSFC STEEL STRUCTURES 8X 4X 8X 12/20/201316

223.25” ” ” ” ” Doublers: 1.5” thickness Plates: 1.85” thickness Spider #1 APPENDIX – RFI – MSFC STEEL STRUCTURES 12/20/201317

Machined Inner Ring Plating: 45 deg Spider #1 APPENDIX – RFI – MSFC STEEL STRUCTURES 12/20/

SPIDER #2 411” (34.25 ft.) 39.2” (3.27 ft.) APPENDIX – RFI – MSFC STEEL STRUCTURES Beams – W36X330 One piece – all welded Weight – 220,000 lb Machined interface plate at 27.5’ D 12/20/201319

Spider #2 Yellow: 1.5” Flange Doubler Plates Hole Diameter: 2.563” Yellow Triangle Plates: 1” Thickness 1.5” Thick Plate Upper Spider Assembly w/ Modifications to Weldment_2_FS_L OXassembly. APPENDIX – RFI – MSFC STEEL STRUCTURES 12/20/201320

W 14x ” THK gusset 28’ Diameter SPIDER #3 12/20/2013APPENDIX – RFI – MSFC STEEL STRUCTURES21 Beams – W14X233 One piece – all welded Weight – 66,000 lb Machined interface plate at 27.5’ D

SPIDER #4 44’ 4” 43” Beams – W36X441 MULTI-piece – welded then bolted via splice plates Weight – ~278,000 lb Machined interface plate at 27.5’ D Quadrant Weldment 50,000 lbs. Cross-Member 61,500 lbs. 12/20/2013 SLS Core Stage Structural Testing

GROUP 3 - PEDESTALS Qty 3 – 3 items, qty 1 of each item General design requirements for each Pedestal: – General Design Geometry Welded wide-flange I-beams stiffened by plates; sections connected via bolted joints Sections (e.g. W14x193) 32’ – 42’ Diameter 20’-34’ Height Plate thicknesses –.5” – 2” Modular design STRESS RELIEF REQUIRED for each Pedestal – Material ASTM A992 Beams Steel plate per ASTM A572, Grade 50 – Tolerances Typical tolerances with some machined surfaces (see charts for details) – Welding CJP welds, groove welds, fillet welds (see charts for typical weld callouts) Gussets welded to flanges/web Welds per AWS D1.1, certified inspection (mag particle/ultrasonic/visual by supplier) – Weight 160,000 lb – 500,000 lb when together; 20,000 – 40,000 lb per section – Transportation All pedestals are MULTI-PIECE delivery 12/20/201323APPENDIX – RFI – MSFC STEEL STRUCTURES

Pedestal #1 12/20/ Pedestal Sections bolted together BEAM SIZE = Vert – W14X193; Hor – W12X53 Weight = ~180,000 lbs (22,500 lb per section) 24APPENDIX – RFI – MSFC STEEL STRUCTURES 42 ft 34 ft

Pedestal #2 and #3 Pedestal #2 Pedestal #3 20’ 21.25’ 10’ 20’ 10’ section 32.4’ ’ 10’ 25 12/20/201325APPENDIX – RFI – MSFC STEEL STRUCTURES

Pedestal #2 and #3 General Beams W14X176 (Vertical) W12X58 (Horizontal) Cross Brace Angles – L6X4X3/4 3” Base Plate 3” Weld Plates Top 3” Weld Plates Opening ¾” Cross Brace Gussets ¾” Cross Brace Splice Plate ½” Section Connection Plates 26 Weight per Section: ~40,000 lbs APPENDIX – RFI – MSFC STEEL STRUCTURES 12/20/ welded pedestal sections bolted together BEAM SIZE = Vert – W14X176; Hor – W12X58 Weight #2 = 160,000 lbs (40,000 lb per section) Weight #3 = 500,000 lbs (42,000 lb per section)

GROUP 4 – REACTION STRUCTURE Qty 13 – 6 items (#1=1; #2-#6=>1) General design requirements for each Reaction Structure: – General Design Geometry Welded wide-flange I-beams stiffened by plates with some bolted joints Welded plate structure Plate structure joined by bolts Some Large I-beam sections (e.g. W36x441) See charts for sizes, geometry, plate thicknesses, etc. STRESS RELIEF REQUIRED for welded Reaction Structure – Material ASTM A992 Beams Steel plate per ASTM A572, Grade 50 ASTM A ksi Ult Tensile for Reaction Structure #3 – Tolerances Typical tolerances for steel structure construction Some machined surfaces (see charts for details) – Welding CJP welds, groove welds, fillet welds (see charts for typical weld callouts) Gussets welded to flanges/web Welds per AWS D1.1, certified inspection (mag particle/ultrasonic/visual by supplier) – Weight 60,000 lb – 600,000 lb – Transportation Some are ONE PIECE delivered to MSFC Others are MULT-PIECE delivery 12/20/201327APPENDIX – RFI – MSFC STEEL STRUCTURES

Reaction Structure #1 Splice Plate Joint (High Stressed Joints) 43’ 59’ Multi-piece welded sections bolted together BEAM SIZE = Vert – W36X441 Weight = 600,000 lbs total (all sections truckable) 12/20/2013 SLS Core Stage Structural Testing

Reaction Structure #1 Base Frame Assembly – 90M13927 BEAM SIZE = W36 X 441 VERT BEAM SIZE = W14 X 193 TUBE SIZE = 14 X 14 X 5/8 Splice Plate Joint (High Stressed Joints) 43’ 21’ 59’ 11’ 12/20/2013APPENDIX – RFI – MSFC STEEL STRUCTURES29

SLS Core Stage Structural Testing Base Frame Assembly Reaction Structure #1 12/20/2013

Reaction Structure #2 12/20/2013 Qty 2 Modular welded sections with bolted X-braces and I-beams BEAM SIZE = W18x330; W18X106 and smaller Weight = 1,200,000 lbs (600,000 lb per tower, TBD weight per modular section; assume all sections truckable) 55’ 37’ 17’ SLS Core Stage Structural Testing

Qty 2 Matl: ASTM A ksi Ult Tensile Other: Spherical Bearings, fasteners, and machined load lugs Weight: ~120,000 lb (60,000 lb each) 4” thick plate and 3” thick plate sandwiched ~19 ft ~11 ft Reaction Structure #3

Qty 2 All welded plate structure Weight: 160,00K lbs (80,000 lb each) 2” thick plate Top Plate and Vertical Plate 1” thick plate Gussets 4” thick plate Base 34 ft 8.5 ft 4 ft Reaction Structure #4

Reaction Structure #5 12/20/2013APPENDIX – RFI – MSFC STEEL STRUCTURES34 50’ 12’15’ Qty 4 Welded tower BEAM SIZE = W18x330; W14X176 Weight = 600,000 lbs (150,00 lb per tower)

157” 108” W 21x101 Beam W 14x61Beam.75” THK Plate.625” THK Plate Reaction Structure #6 Qty 2 Welded beam structure Weight: 13,000 lb (6500 lbs each) 12/20/2013APPENDIX – RFI – MSFC STEEL STRUCTURES35