ula rocket factory tour

Site visit: The factory where Vulcan rockets are being built

By cat hofacker | august 29, 2019, the united launch alliance rocket's first flight will carry a lunar lander.

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DECATUR, Alabama — There’re many sights you might expect to see when visiting a rocket factory: machinery, half-assembled pieces, maybe even a complete rocket if you’re lucky.

What might be unexpected are the golf carts that are the most common method of transportation here at the United Launch Alliance facility. Everywhere I look, engineers zoom from one end of the 1.6-million-square-foot building to the other, careful to steer around the silver rings and domes on the floor that will soon be parts of the first Vulcan Centaur, the rocket ULA is counting on to launch everything from small satellites to astronauts to low Earth orbit and beyond.

“We know Vulcan is our future,” Zeke Terry, a ULA project manager who’s heading Vulcan manufacturing, tells me as he ferries me around the facility where Vulcan will come to life.

That’s not the only work that goes on here, of course. The Decatur building has been home to both Boeing’s Delta and Lockheed Martin’s Atlas rockets since 2006, when the two companies’ launch divisions joined forces to create ULA, a separate entity that does national security launches for the U.S. military and the National Reconnaissance Office spy-satellite agency, as well as for NASA and NOAA. The facility has about 30 upper and lower stages in various phases of production for the next several Atlas and Delta launches, plus a completed Vulcan booster for structural testing.

We start our tour at the northeast corner of the factory, where the first pieces of hardware for Vulcan’s first flight are coming together. Terry shows me inch-thick sheets of aluminum that will be pressed by machines between two blunt knife edges and curved to form the outer shell of a Vulcan booster. Some still-flat sheets hang next to the machine, awaiting their turn in the press, indistinguishable from the sheets that will encase an Atlas booster except for the different pattern marking what will be the inside of the panels.

That similarity is intentional. The new design will have many of the same components as the Atlas V rockets in order to streamline production. ULA announced the Vulcans in 2015 and began manufacturing this year. The biggest overlap is the Centaur III upper stage on Atlas that is being enlarged to hold two engines instead of one.

“The objective for us was to take the best of both worlds from the two and make it into one,” Terry says. “Each one of those engineering designs went through an analysis to say what did we have, what is the best to give us the most efficient, cheapest vehicle that we can build to make sure that we can launch on time, a 100% mission success and be competitive.”

Vulcan is on track for its 2021 debut, ULA CEO Tory Bruno told me last week at AIAA’s Propulsion and Energy Forum in Indianapolis, and the company is “confident to go directly to real missions with real customers on our first flights.”

ULA announced earlier this month that Vulcan’s first flight will be launching the Peregrine lunar lander from Astrobotic, one of two companies NASA has tasked with sending robotic landers to the moon ahead of the 2024 landing under the Commercial Lunar Payloads Services program, or CLPS . The second flight is scheduled for later that year with the first of six cargo resupply missions with Sierra Nevada Corp.’s Dream Chaser vehicle to the International Space Station.

But before production on the Vulcans that will launch those missions can begin in earnest, the rocket’s main components must be tested. Terry lays out the timeline as we zoom back to the entrance of the production floor: Testing with the structural test booster will begin in September, and two test articles of the Centaur upper stage are next in line. They will be sent to NASA’s Marshall Space Flight Center in Huntsville in 2020.

Once that’s done, “we’re focused on the first flight and making sure we have a vehicle to fly,” Terry says.

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Take a look inside ULA’s Rocket Factory in the company’s latest video

In a four-minute “How It’s Made” style video, ULA takes viewers inside its Decatur, Alabama rocket factory to see where the company makes its Delta, Atlas, and Vulcan rockets.

Everyone is familiar with what a video of a rocket launch looks like, but it takes a lot of work to get to the couple minutes of launch. This look inside the factory shows a lot of the behind-the-scenes work, from the friction-stir welding to the SOFI (Spray-On Foam Installation).

The video is a very surface-level tour, addressing the major steps taken to build orbital class rockets without getting bogged down by the details.

The approachable video may not provide any ground-breaking new information, but it’s interesting enough for even die-hard space fans to enjoy, with some cool new footage of the manufacturing process, and digestable enough for even a class of school kids. Check it out:

If you’ve found ULA’s video tour interesting, you should definitely check out the factory tour with ULA CEO Tory Bruno from Smarter Every Day . The tour is almost two years old now, but he really give a fantastic first-person perspective of the facility and asks a lot of questions. The hour-long video is well worth a watch if you want to know a bit more about the facility.

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Tour - ULA Rocket Factory

Itinerary   (all times are approximate):

• 12:40 PM CST, Fri Jan 27 - arrive at main gate
• 1:00 PM - tour begins
• 3:00 PM - tour concludes
• 3:15 PM - social at local watering hole

Note that all guests must abide by all relevant ULA facility rules & regulations ( https://www.ulalaunch.com/docs/default-source/visitor-guides/ula_decatur_visitor_guide.pdf ). Among other things, this means no photography, wear pants, and US citizens only. Registration opens Monday December 5th 8:00 CST and closes Tuesday January 10th 17:00 CST. Please reach out if you have any questions, comments, or concerns.

This event is brought to you by the American Institute for Aeronautics & Astronautics (AIAA), Greater Huntsville Section (GHS), Young Professionals (YP) committee. www.eventbrite.com/e/tour-ula-rocket-factory-tickets-479722722577

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Saints Alive Tour of ULA Rocket Factory

June 21, 2023.

The Saints Alive will tour the United Launch Alliance (ULA) Rocket Factor y in Decatur on Wednesday, June 21 . The bus will leave Grace at 9:00 am for a 10:00 am – 12:00 noon walking tour. There have been major changes to the factory since 2016. Those who have been previously will not recognize the 1.5 million square foot building now. There will be quite a bit of walking, but they will provide two carts which will each hold 5 people. Please note if you would like to ride on a cart. Lunch will follow the tour at a restaurant in Decatur.

The sign-up sheet is posted on the bulletin board in the church narthex or contact Gene Menzel. You must sign up by June 12. In order to participate you must be a U.S. citizen with an unexpired driver’s license or other form of government-issued identification. No copies or photos of identification will be accepted. See Gene Menzel for the dress code and other guidelines.

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BE-4 Engines Arrive For ULA Vulcan Cert-2

The second of two Blue Origin BE-4 engines has arrived at United Launch Alliance’s (ULA) Decatur, Alabama, factory for installation on a Vulcan rocket targeted for launch this fall.

The mission, known as Certification-2 (Cert-2), is the second of two demonstration missions required for national security space launches (NSSL) aboard ULA’s new Vulcan rocket. ULA sold the Cert-2 launch service to Sierra Space for the debut run of its Dream Chaser spaceplane on a cargo run to the International Space Station (ISS) for NASA.

“We expect them to be ready in the fall,” ULA CEO Tory Bruno wrote on X, formerly known as Twitter.

The first Dream Chaser spaceplane, Tenacity, is completing thermal vacuum testing at the NASA Armstrong In-Space Propulsion Facility in Sandusky, Ohio. It will then be trucked to Kennedy Space Center for additional testing, including electromagnetic interference and acoustic evaluation, as well as taxi and tow tests before it is mounted atop Vulcan, loaded with cargo and launched.

“Our team has been working around the clock to prepare for Dream Chaser Tenacity’s arrival at NASA Kennedy, offloading four semi-tractor trailers of support equipment inside the Space Station Processing Facility (SSPF),” Sierra Space wrote on X.

ULA has sold more than 70 Vulcan launches to date, including 38 missions for Amazon’s Project Kuiper and multiple NSSL missions under the Phase Two program. The rocket debuted on Jan. 8 with the successful Cert-1 launch, which dispatched the Astrobotic Peregrine lunar lander toward the Moon.

Irene Klotz is Senior Space Editor for Aviation Week, based in Cape Canaveral. Before joining Aviation Week in 2017, Irene spent 25 years as a wire service reporter covering human and robotic spaceflight, commercial space, astronomy, science and technology for Reuters and United Press International.

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End of an era: Last ULA Delta IV Heavy triple-core rocket to lift off from Cape Canaveral

M arketed as "the most metal of rockets," United Launch Alliance's massive triple-core Delta IV Heavy roars to life amid a blazing hydrogen fireball on the launch pad, with raging flames billowing and blackening its orange boosters seconds before liftoff.

Heavy-metal-music pyrotechnic comparisons aside, Rob Long has a soft spot for the retiring mega-rocket — as do many of thousands of employees involved with the program the past two decades on the Space Coast. He worked for 3½ years as the National Reconnaissance Office's mission manager preparing for the agency's first Delta IV Heavy launch: NROL-26 in January 2009 from Cape Canaveral.

And Long said he considers the Delta IV Heavy "near and dear to my heart."

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Cape Canaveral: Is there a launch today? Upcoming rocket launch schedule for SpaceX, NASA in Florida

“That was a great learning experience. You learn soup-to-nuts on how to take a satellite and put it on a launch vehicle,” recalled Long, who is now president and CEO of Space Florida.

Now, ending an era in American spaceflight, the 16th and final Delta IV Heavy rocket is scheduled to lift off at 1:40 p.m. Thursday from Launch Complex 37 at Cape Canaveral Space Force Station. However, ULA officials reported that the forecast only shows a 30% chance of favorable weather conditions. 

The mission marks the 389th and last flight of the Delta program, which dates to 1960. ULA is replacing the retiring rocket with the next-generation Vulcan, which logged a successful maiden flight in January from the Cape. Crews can configure the flexible, less-expensive Vulcan with zero, two, four or six solid-rocket boosters to accommodate an array of orbital missions.

"We're into reusability, and we're into new ways of doing business. On one hand, it's nostalgic. And it's personally a great memory for me. But at the same time, I think it speaks to just moving forward in the industry — and not looking back," Long said.

Tune in Thursday to  floridatoday.com/space for FLORIDA TODAY Space Team live coverage and updates on the last Delta IV Heavy launch, starting about two hours before liftoff.

The historic rocket will soar skyward with a classified payload on the NROL-70 national security mission, conducted in tandem with the NRO and the Space Force’s Space Systems Command. The massive rocket launches the NRO's heaviest satellites.

ULA CEO: 'It's a beautiful rocket'

FLORIDA TODAY asked ULA President and CEO Tory Bruno about the Delta IV Heavy retirement last month during an interview at the SpaceCom convention in Orlando.

“It’s a beautiful rocket. It’s launched amazing missions. It’s the most metal of all rockets, as I like to say — it sets itself on fire before going to space,” Bruno said.

“I just love it. And so, we’re all going to miss it. So it’ll be bittersweet,” he said.

Why does the Delta IV Heavy seem to "emerge from a cloud of fire" at liftoff? A ULA video explains that the fireball is created by buoyant hydrogen gas that ignites before the engines come up to power.

Bruno noted that he discussed the rocket's fiery characteristics with the Swedish heavy metal band Sabaton, one of his favorite bands, when he attended their concert in Denver in September 2022.

"We brought them a Delta IV Heavy model. We were in the back with them in their green room. They were getting rocket science lessons, and they knew it was the most metal of all rockets — but they wanted to know why. So we had fun with them," Bruno said.

Delta IV Heavy debuted in 2004

The Delta IV Heavy debuted during a December 2004 demonstration flight from Launch Complex 37. At that time, it was the most powerful rocket launched from Cape Canaveral save the Saturn V and space shuttles.

Three years later, the inaugural Delta IV Heavy mission with a payload launched in November 2007 from the Cape, lifting a U.S. Air Force satellite designed to provide early warning of intercontinental ballistic missile launches. Long's NROL-26 mission in January 2009 represented the rocket's second mission and third overall flight.

Long was an Air Force captain when he started his 3½ years of mission-management duties, then got promoted to major by liftoff. He went on to command Space Launch Delta 30 as a colonel at Vandenberg Space Force Base in California.

According to a Space Force summary, the Delta family of rockets, which includes smaller models such as Delta II, has delivered a wide array of payloads "including military, government, and commercial weather, communications and science satellites, robotic probes for exploration , eight Mars rovers, and one telescope" during the past 60-plus years.

“These launches place critical capabilities into orbit for our nation and our allies in what are dynamic times for the space community," Col. Jim Horne, senior materiel leader for Space System Command's Launch Execution Delta, said in a press release ahead of the final launch.

"Every member of our launch team understands what’s at stake and works with care and efficiency to prepare for what’s going to be a tremendous launch,” Horne said.

Last launch 'will be one for the books'

ULA's mission preparation timeline for the last Delta IV Heavy launch:

• May : The rocket arrived at Cape Canaveral aboard ULA's R/S RocketShip, a 312-foot cargo vessel, after a trek from the company rocket factory in Decatur, Alabama.
• December : Crews raised the rocket upright at Launch Complex 37.
• Feb. 26 : Encapsulated inside a 5-meter-wide fairing, the NROL-70 payload was delivered to the pad and hoisted atop the rocket, boosting the vehicle's height to 235 feet. 

After the NROL-70 mission wraps up, SpaceX officials hope to soon take over Launch Complex 37 and "modify, reuse or demolish" ULA's infrastructure to create a new Starship-Super Heavy launch base by 2026.

Air Force officials are working on a Starship environmental impact statement  with NASA, the Federal Aviation Administration and the U.S. Coast Guard. Two weeks ago, Space Force officials collected public comments on the proposal during open houses in Cocoa, Titusville and Cape Canaveral. A virtual public meeting featuring a narrated slideshow is online at  spaceforcestarshipeis.com .

The Kennedy Space Center Visitor Complex is selling Delta IV Heavy launch viewing tickets for $70. Spectators will travel by bus past the KSC gates to the Apollo/Saturn V Center to watch the huge rocket lift off beyond Banana Creek.

“Being located on an active spaceport, we have seen many milestone launches here at Kennedy Space Center Visitor Complex. And the last launch of the Delta IV Heavy will be one for the books,” Therrin Protze, visitor complex COO, said in an email.

“Celebrating this final launch here at the visitor complex, where guests can see many history-making rockets — including two earlier Delta rockets in our rocket garden — is an unmatched experience that we are excited to bring to our visitors," Protze said.

Rick Neale  is a Space Reporter at FLORIDA TODAY (for more of his stories,  click here .) Contact Neale at 321-242-3638 or  [email protected] . Twitter/X:  @RickNeale1

Space is important to us and that's why we're working to bring you top coverage of the industry and Florida launches. Journalism like this takes time and resources. Please support it with a subscription here.

This article originally appeared on Florida Today: End of an era: Last ULA Delta IV Heavy triple-core rocket to lift off from Cape Canaveral

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Russia set to build new space center in Moscow (PHOTOS)

Russia’s new National Space Center is being constructed on the site of the Khrunichev State Space Research and Production Center in western Moscow.

On June 21, the Moscow City Architecture Committee approved the urban planning solution, according to the official website of the Moscow Mayor’s Office.

The tender to develop the architectural concept, announced in October 2019, was won by the Russian design bureau UNK Project.

According to their concept, the main component of the center will be a triangular tower in the form of a 248m-tall rocket, which will house the headquarters of Roscosmos. The facade of the building will be illuminated to create a moving-up effect. And at the base, lighting fixtures will simulate the flame of a rocket booster.

Adjoining the tower will be a long building with research labs and offices. This building will be traversed by a 545m-long central gallery, along which canteens and consumer services will be located.

In addition, the complex will feature open-air museums in U-shaped courtyards, where pieces of aerospace equipment will be suspended in the air via cables between the buildings.

The ceremonial laying of the first stone took place in September 2019, and construction is scheduled to finish by 2022.

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City Break St. Petersburg & Moscow

About the tour.

MOSCOW is illuminating reflections … Moscow is the capital and most populous city of Russia. Situated on the Moskva River in the Central Federal District of European Russia, the city is well known for its architecture, particularly its historic buildings such as Saint Basil's Cathedral in Russian architectural style with a richly decorated and multicolored facade. St.PETERSBURG is a stroll along a historic canal… Saint Petersburg is a city situated on the Neva River, at the head of the Gulf of Finland on the Baltic sea. It is Russia's second-largest city after Moscow. Another nickname of St. Petersburg is The City of White Nights because of a natural phenomenon which arises due to the closeness to the polar region and ensures that in summer the nights of the city do not get completely dark for a month. Saint Petersburg is home to the Hermitage, one of the largest art museums in the world.

• 3 Nights’ accommodation in Moscow at Izmaylovo Delta 4 Star Hotel or similar
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Alfa Izmaylovo (Sigma plus) or Similar

3 night(s) in Moscow

Oktyabrskaya Hotel or Similar

3 night(s) in St. Petersburg

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• Package Validity - 31 MAR 2023
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Border Patrol Boat AK-223 - Project 1204 “Shmel” (USSR)

The first river artillery boats (armored boats) were developed in 1935 for actions on rivers, lakes and sea shallows. The tank gun turrets, the armored car machine-gun turrets and rocket weapon (the “Katyushas») were mounted on them. During the Great Patriotic War 1941-1945 the armored boats were com¬missioned to the river and lake flotillas.

In the late 1950's — early 1960's. the Soviet Union had ceased designing new artillery armored vehicles. But in 1965, the Navy together with Minsudproma approved the design task river gunboats (ACA) of the project in 1204 (code "Shmel" (Eng: Bumblebee)). With all of this all are in service with the BCA in 1965 were also reclassified AKA, almost becoming the founders of the "new" subclass combat boats. It was designed for patrol duties on rivers and lakes, vessels and boats combat sweep, artillery shooting assistance for ground forces; troops with armament carrying during crossing and acting in river basins; largely unsuitable for open seas operations, but can be used for protecting harbors and acting littoral and shallow-water seas areas.

Head boat Project 1204 (Shmel class — as litsezreem, Western designation coincided with a real cipher) was built in Kerch at the shipbuilding factory "Zaliv" (Eng: The Bay) in 1967. It was built 118 artillery armored gunboats by the project 1204 from 1967 until 1974 in total.

CONSTRUCTION, NAME

AK-223 was laid down at Shipyard named after 61 Communards in Nikolaev. Commissioned on June 22, 1969.

PERFORMANCE

• Speed: 24 knots
• Range: 320 nautical miles (10 knots), 240 nautical miles (20 knots)
• Autonomy: 7 days
• Crew: 14 men (1 officer)
• Displacement: full load - 71 tonnes
• Length: 27,4 meters
• Beam: 4,32 meters
• Draft: 0,85 meter
• 1x1 76-mm PT-76B artillery mount
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Photo #211 taken on May 01, 2014 during tour of open-air Weaponry and Fortification Exposition in Victory Park on Poklonnaya Hill with my dear client from Spain, Carmelo Gonzalez Santana

About Me in Short

My name's Arthur Lookyanov, I'm a private tour guide, personal driver and photographer in Moscow, Russia. I work in my business and run my website Moscow-Driver.com from 2002. Read more about me and my services , check out testimonials of my former business and travel clients from all over the World, hit me up on Twitter or other social websites. I hope that you will like my photos as well.

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The entrance into the Museum of Wooden Architecture And Peasants' Life at winter twilight. The museum was established in Suzdal in 1960s and spread out on the right, high bank of the Kamenka River. At the right from the entrance is rising to the darken skies an elegant wooden church of Transfiguration that was built in 1756 in Kozlyatyevo village.

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