1. Solid Rocket Booster Processing
Kennedy Space Center
SRB Mechanical Engineering
NE-M7

2. KSC – Solid Rocket Booster (SRB) Processing Areas
Shuttle Processing and Launch
Postflight Hardware Recovery and Evaluation

3. KSC – Solid Rocket Booster (SRB) Processing Areas
Pad
VAB
RPSF

4. KSC – Solid Rocket Booster (SRB) Processing Flow
Recovery
Disassembly and Assessment
Design Centers
Element Refurbishment and Manufacturing
Logistics and Shipping
Delivery
Offload and Inspect
Aft Booster Build
RPSF
SRB RETRIEVAL
SHIP
SHUTTLE
LANDING
HANGAR AF
ORBITER PROCESSING
FACILITY
SRB STACKING
Field Joint Mate
Leak Test
Field Joint Protection System
S&A
Offload
Buildup
ET/SRB
OPERATIONS
INTEGRATED
VEHICLE OPS/VAB ET
STANDALONE
LCC
HORIZONTAL
PAYLOAD INT
PAYLOAD FACILITIES
HYPERGOLIC
FACILITY
VERTICAL
PAYLOAD
INSTALLATION
Launch
Pad Ops

5. Forward Assembly and Aft Skirt arrive from SRB Element in the Assembly Refurbishment Facility (ARF) at KSC.
Aft Skirt
Parachutes
ARF
Frustum
Forward Assembly
Nose Cone
Frustum
Parachutes
Forward Skirt
Nose Cone

6. Segments arrive from ATK in Corrine, Utah in rail cars
Segments arrive from ATK in Corrine, Utah in rail cars. The segments go to the Rotation, Processing and Surge Facility (RPSF) at KSC.
RPSF

7. At the Rotation, Processing and Surge Facility (RPSF), the rail cover is removed, propellant grain & metal surfaces inspected, the segments are rotated to vertical, secured on a pallet and stored in the surge facilities.
Break-over of the forward segment from horizontal to vertical

8. Build-up to Aft Booster Configuration (see following charts)
At the RPSF, the aft booster is assembled and processed in the build-up stands. Other hardware processed in the RPSF includes: - Stiffener Rings Assembly and Closeouts - Thermal Curtains - External Tank Assembly (ETA) ring and hardware - Thermal Protection System (TPS) closeouts - Systems tunnel and cables installation and closeouts - Heater power cable installation - Nozzle severance cable connection
AEC Mate
AEC Breakover
Aft Skirt Mate
Aft Segment Breakover to Vertical
Build-up to Aft Booster Configuration (see following charts)
Aft Booster Build-up Stand

9. Pin Retainer Steel Strap Aft Booster Build Stand
The aft skirt is placed in the build-up stand and the booster segment is mated. 177 pins are installed and secured with a steel pin retainer strap. The joint is closed out with cork and RT-455 ablative compound.
Aft Skirt Mate
Pin Retainer Steel Strap
Cork Band
Aft Booster Build Stand
Aft Skirt Clevis

10. Aft exit cone is assembled to the forward exit cone at the RPSF.
Phenolic mating surfaces are primed with DC1200 primer prior to assembly.
Primary and secondary seals (O-rings) are installed.
Exit cone is raised on an elevator and floated on an air bearing for mating.
The joint is bolted with 96 fasteners.
Leak test is performed at 83 and 30 psig with the mass flow meter prior to joint RTV backfill. The joint gap is backfilled (injected) with RTV silicone sealant as part of thermal barrier system.
Primary Seal
Secondary Seal
Phenolic
RTV Thermal Barrier
AEC Mate
Phenolic
Aft Skirt Not Shown for Clarity
Aft Exit Cone

11. Surge buildings protect hardware from elements (rain, wind, etc.)
If needed, the aft booster will be put into surge for storage. The SRM transporter transfers the aft booster from the RPSF to the surge or the Vehicle Assembly Building (VAB) for the stacking operations.
Surge buildings protect hardware from elements (rain, wind, etc.)
Not climate controlled
Segments have weather proof covers on top
RPSF
Surge
VAB

12. The segment is connected to the beam and the 325-ton crane in the transfer isle of the VAB. Circularity measurements, tang preps, metal parts inspections, abrade J-leg, and assemble/connect curtain.

13. The aft booster segment is lifted from the transfer isle to the high bay of the VAB to be connected to the Mobile Launch Platform (MLP). The booster is bolted to the hold down post of the MLP with a frangible nut that separates at launch.

14. At KSC, the center and forward segments are stacked
At KSC, the center and forward segments are stacked. When two segments are mated at KSC, this joint is called a field joint. The SRB forward assembly mated. Then, all field joints are all closed out in the VAB.
SRB Forward Assembly
Forward Segment
Forward Field Joint
Forward Center Segment
Center Field Joint
Aft Center Segment
Aft Field Joint
Aft Booster

15. All the field joints are configured with a tang and clevis design with a capture feature. The 3 O-rings and J-leg help prohibit a combustion gas leak at the joints.
Field joint is a clevis and tang configuration with 177 pins
Three alignment slots/pins ensure correct segment clocking
Tang “capture feature” and insulation “j-leg” added during redesign
Tang
Tang capture feature “captures” inner clevis leg to limit seal surface movement (joint rotation) during motor pressurization
Insulation j-leg prohibits combustion gas from reaching seals
Capture Feature
Field Joint Example
Clevis
Inner Clevis Leg
Insulation J-leg

16. For a segment mate, the segment is lowered over the SRB stack
For a segment mate, the segment is lowered over the SRB stack. The field joint assembly fixture (FJAF) acts as a “shoehorn” to align the tang/clevis and prevent flat-on-flat metal conditions. Leak test of the joint and the vent port plug are the final acceptance of a successful joint mate.
Field joint mate with 3 feet between the segments.
FJAF
O-rings
PSA Application
Field joint mate with 1/8” between the segments.
Segment mates require a controlled environment within the curtain room. Also, the controlled area requires personnel to wear flames, eyes-only hoods, gloves and meet maximum static levels.

17. Each field joint is closed out with the field joint protection system (FJPS). The FJPS provides thermal protection, weather protection and retains joint pins.
Cork
Joint Temperature Sensor
Heater Retainer Strap and Thermal Barrier
Joint Heater
Field joint after mate, before FJPS
RT-455 Ablative
Cork
Pin Retainer Band
RT-455 Ablative
Field joint with FJPS

18. The forward assembly is mated to the forward segment and also closed out with FJPS. Since no propellant is exposed in this mate, a controlled environment is not needed.
Forward Skirt
Cork Band
Fwd Segment
Forward Skirt JPS
Pin Retainer Strap
Forward Skirt Joint

19. The systems tunnel, cables, heater power cables, and linear shaped charge (LSC) are all assembled and closed out. In addition, TPS, cabling and closeouts are completed in other areas of the boosters.
Forward and Center Field Joint Tunnel Closeout
Tunnel Cover
RT-455
Systems Tunnel Closeout LH side (fwd 3 segments)
Heater Power Cables
Cork

20. After the boosters are assembled, the external tank (ET) is then brought over from the ET check-out cell in the VAB for the ET/SRB mate.

21. Next, the orbiter is mated to the ET with the boosters supporting the weight of the whole shuttle.

22. The crawler transports the MLP and the shuttle to the pad where all processing is completed.

23. After launch, the boosters separate at around L+128 seconds
After launch, the boosters separate at around L+128 seconds. The boosters continue to climb to around 42 miles high. Then, boosters tumble until the drogue shoot deploys at 1600 feet, which orientates the boosters upright. The main parachutes deploy at 6300 ft to slow down the boosters to impact the ocean at about 60 mph. Before impacting the ocean, the aft exit nozzle separates to prevent deformation on the reusable motor.

24. The Liberty Star and Freedom Star each retrieve a booster in the ocean to tow it back to Hanger AF at KSC.

25. The boosters are received at Hanger AF and evaluated for any off nominal conditions in the post-flight assessment.

26. Every aspect of the boosters is inspected and compared to past post-flight data. The segments are disassembled and sent back to ATK and USA.