NASA/TM-2013-217910

Refractory Materials for Flame Deflector Protection

System Corrosion Control:
Similar Industries and/or Launch Facilities Survey
Luz Marina Calle
NASA Kennedy Space Center
Paul E. Hintze
NASA Kennedy Space Center
Christopher R. Parlier
NASA Kennedy Space Center
Brekke E. Coffman
NASA Kennedy Space Center
Jeffrey W. Sampson
NASA Kennedy Space Center
Mark R. Kolody
ASRC Aerospace Corporation
Jerome P. Curran
ASRC Aerospace Corporation
Stephen A. Perusich
ASRC Aerospace Corporation
David Trejo
Texas A&M University
Mary C. Whitten
University of Central Florida
Jason Zidek
Versabar, Inc.

January 2009
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NASA/TM-20 13-217910

Refractory Materials for Flame Deflector Protection System

Corrosion Control:
Similar Industries and/or Launch Facilities Survey
Luz Marina Calle
NASA Kennedy Space Center
Paul E. Hintze
NASA Kennedy Space Center
Christopher R. Parlier
NASA Kennedy Space Center
Brekke E. Coffman
NASA Kennedy Space Center
Jeffrey W. Sampson
NASA Kennedy Space Center
Mark R. Kolody
ASRC Aerospace Corporation
Jerome P. Curran
ASRC Aerospace Corporation
Stephen A. Perusich
ASRC Aerospace Corporation
David Trejo
Texas A&M University
Mary C. Whitten
University of Central Florida
Jason Zidek
Versabar, Inc.

National Aeronautics and

Space Administration
Kennedy Space Center

January 2009
NASA/TM-20 13-217910

Available from:

NASA Center for AeroSpace Information National Technical Information Service

7115 Standard Drive 5301 Shawnee Road
Hanover, MD 21076-1320 Alexandria, VA 22312

Available in electronic form at http://www.sti.nasa.gov.

11
 NASAffM-20 13-217910

Executive Summary

Refractory concrete is used to protect National Aeronautics and Space Administration (NASA)
launch structures from elevated temperatures, ablation, and erosion. The only refractory material
qualified for use at Launch Complex 39A (LC 39A) and Launch Complex 39B (LC 39B) is
Fondu Fyre W A-1 G which is supplied by the Pryor Giggey Co. The material was developed
solely for NASA in the 1960s.

Refractory concrete at LC 39A and LC 39B has become susceptible to failure, resulting in large
sections of the material breaking away from the base structure. During launch, these sections
become high-speed projectiles that jeopardize the safety of KSC personnel, and have the
potential to damage ground support equipment and the Space Shuttles.

A review of the current specification and requirements for refractory materials indicates that the
test methods and qualification criteria are not well defined. Consequently, the only refractory
product qualified for use at the Kennedy Space Center (KSC) may not have the material
properties necessary to survive extended exposure to Florida coastal environments and the severe
launch conditions exhibited by the Space Shuttle. As a result, better performing refractory
materials may be available for use at KSC.

A literature search was conducted to ascertain the different categories of refractory materials that
are available for the protection at KSC's launch pads. The classes of materials were categorized
as follows:

• Firebrick
• Refractory Concrete
• Silicone and Epoxy Ablatives

Based upon this information, a literature survey was conducted to locate industries that had
refractory requirements that were similar to NASA's. Based upon this survey, site visits, and
interviews with pertinent industry personnel and refractory vendors were conducted. An analysis
of refractory materials at the following locales was then initiated:

• Stennis Space Center

0 A-2 Test Facility
0 Bl and B2 Test Facilities
0 E-2 Test Facility
0 E-3 Test Facility
0 Bldg 3300

• Cape Canaveral Air Force Station

0 Launch Complex 17
0 Launch Complex 34
0 Launch Complex 36
0 Launch Complex 37
0 Launch Complex 40
0 Launch Complex 41

Ill
NASA/TM-20 13-217910

• Vandenberg Air Force Base

o Launch Complex 6
• Palm Beach County Fire Training Facility

As a result of the site visits and interviews, a series of products for launch applications were
found.

Firebrick, while historically used near flame deflectors at NASA launch sites, was not found at
any of the locales investigated in this report. Product and labor costs associated with the
installation of the materials were cited as the driving factors for its lack of use.

Refractory concrete was used at numerous launch locations. Currently used products include
Fondu Fyre WA-1G and Fondag DG. Both versions are gunnable, and as a result, benefit from
reduced labor costs associated with the application of the product. Kruzite GR Plus is another
refractory concrete that is noteworthy. Kruzite GR Plus is gunnable and provides better adhesion
(less rebound) when used in overhead flame duct locations.

The direct impingement areas (of the flame deflectors) were often found to be protected by a
ceramic-filled epoxy called Martyte. Martyte was often used to replace and protect refractory
concrete that had deteriorated. Furthermore, structural steel (in direct impingement areas) was
often protected by the product.

Havaflex is a phenolic ablative that is produced by Ametek Chemical Products. It can be either
troweled or sprayed as required, and is used in areas that are subject to direct rocket exhaust.

Various silicone ablative materials were used outside direct blast areas. These coatings included
the General Electric GE 3404 ablative, as well as other proprietary formulations from other
manufacturers and aerospace companies. These products are often used to protect structural steel,
launch pad tubing, and connectors for launch pad instrumentation.

None of the products in this trade study can be considered a panacea for LC 39A and LC 39B.
Fondag DG, while inexpensive, was often top-coated with Martyte for repair or additional
thermal protection.

Martyte is costly and difficult to apply. Furthermore, incompatibilities between Martyte and the
silicone ablatives may be of concern.

Havaflex is a phenolic ablative material that is easy to apply; unfortunately, it is costly and
requires frequent replacement.

The silicone ablatives are inexpensive, easy to apply, and perform well outside of direct rocket
impingement areas. When used in locations subject to direct rocket exhaust, the performance of
the coating is exceeded by refractory concrete and the epoxy alternatives.

This report summarizes the ablative materials that were found at industries with refractory
requirements that are similar to NASA's. The refractory products may be considered for use at
LC 39A and LC 39B provided the appropriate testing requirements and specifications are met.

IV
 NASA!fM-20 13-2 17910

Contents

1 INTRODUCTION ........................................... ........................ .......................... 1

1.1 Objectives of the Exploration Technology Development Program
(ETDP) Refractory Studies ....................................... ......................................... 1
1.2 Current Task ........................ ......... .................... ....................... ........................... 2
1.3 Launch Environment .................................................................................. ........ 2

2 ASSETS EVALUATED IN THIS ANALYSIS .............. ................................. .4

3 DETERIORATION AND REPAIR OF REFRACTORY MATERIAL

USED AT LC 39A AND LC 39B ...................................... ............ ........ ......... 10

4 GENERAL CATEGORIES OF REFRACTORY MATERIALS FOR

LAUNCH APPLICATIONS ........................ ................................................... 13
4.1 Firebrick .............................................................. .......... ................................... 13
4.2 Refractory Concrete ................................................................ ... ;..................... 15
4.3 Epoxy and Silicone Ablatives .......................................................................... 16

5 MATERIAL INVESTIGATIONS BY SITE .......... ........................................ . 17

5.1 Stennis Space Center ........... ........................ .. ............ ........... ............................ 17
5.1.1 A-2 Test Stand ................................................................................................. 18
5.1.2 B-1 and B-2 Test Stands ...... ........................................................ .................... 20
5.1.3 E-2 Test Facility ............................................................ .... .......... ..................... 23
5.1.4 E-3 Test Facility ............................................................ .... ..... ........ .................. 25
5.1.5 Bldg. 3300 Stennis Space Center ............................ .. ............ ........................... 27
5.2 Cape Canaveral Air Force Station Launch Facilities .............. ......................... 29
5.2.1 Launch Complex 17 ............ .......................................... .......... ......................... 29
5.2.1.1 LC 17A ............................... .............................................................................. 31
5.2.1.2 LC 17B ............................................................................................................. 34
5.2.2 Launch Complex 34 .... ..................................................................................... 40
5.2.3 Launch Complex 36 .............................. ...........................................................42
5.2.4 Launch Complex 37 ..................... .................................................................... 43
5.2.5 Launch Complex 40 ................................ ........................... .......... .. .................. 44
5.2.6 Launch Complex 41 ......................................................................................... 45
5.3 Vandenberg Air Force Base: Launch Complex 6 ...... .............. ........................ 46
5.4 Palm Beach County Fire Training Facility ..................................................... .47

6 CONCLUSIONS ..... ......................................................................................... 50

APPENDIX A. PRODUCT DATA SHEETS ..... .. .......... .................... ,..................................... 55

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NASA/TM-2013-217910

Figures

Figure I. KSC Launch Complex 39B ......... ............................... ................... ... ................. 5
Figure 2. Space Shuttle Launches by Year and Complex ................................................. 7
Figure 3. Cross Section of Flame Deflector at Launch Complex 39A .............................. 8
Figure 4. Openings for Flames From the Main Engine and SRBs ....................................9
Figure 5. Magnified View ofLC 39A Flame Deflector.. ............................................... .IO
Figure 6. Evidence That a Section of Concrete Was Dislodged During the
Launch of STS-126 ............................ .. ............................................ ................ 11
Figure 7. Section of Concrete That was Dislodged During the Launch of STS-
126 ......... ...................................... ................................................................ ..... 12
Figure 8. Firebricks at the Base of Launch Complex 34 ................................................. 13
Figure 9. Firebrick at Launch Complex 34 ....................... .............................................. 14
Figure 10. Damaged Walls at LC 39A .......... ......... .................... ....................................... 14
Figure 11. Stennis Space Center Location .... .................... ................................................ 18
Figure 12. Exterior View ofthe A-2 Test Stand ... ........................................... ......... ...... .. 18
Figure 13. View ofthe A-2 Flame Duct and Diffuser. ...................................................... 19
Figure 14. Holes Drilled Into the Surface of the Steel A-2 Test Stand ............................. 20
Figure 15. Rocket Motor Test at Stennis B-1 Complex .................................................... 21
Figure 16. Stennis B-2 Flame Deflector ............................................................................ 22
Figure 17. Drain Holes at the Base of the B-2 Flame Deflector .......................................22
Figure 18. E-2 Cell I Test Stand at Stennis Space Center ................................................ 23
Figure 19. Stennis Space Center E-2 Cell2 Vertical Test Flame Duct.. ........................... 24
Figure 20. Refractory Concrete on Walls and Floor of Stennis E-2 Cel12 Flame
Deflector .......................................................... .. ....................... ............ ........... 24
Figure 21. E-3 Vertical Test Cell Flame Duct at Stennis Space Center.. .......................... 25
Figure 22. E-3 Vertical Test Cell Flame Duct at Stennis Space Center - After
Firing .............................. ................................. ... .... ................. ...... ................... 26
Figure 23. Close-up view of Damage to E-3 Cel12 Test Stand ......... ............................... 26
Figure 24. Fondu Fyre Blocks at the Stennis Space Center E-3 Location ........................ 27
Figure 25. Test Duct at Stennis Space Center ................................................................... 27
Figure 26. Refractory Concrete Apron at Stennis Space Center ............................... ........ 28
Figure 27. Stennis Plume Deflector Test Rig ............................................ ........................ 29
Figure 28. Aerial View ofLC 17 .......................... ........................................................... 30
Figure 29. Major Structures at LC 17 ................................................................................ 31
Figure 30. Underside of LC 17A Flame Deflector. .................................. ......................... 32
Figure 31. Flame Deflector at LC 17A .............................................................................. 33
Figure 32. Fondu Fyre Patched Areas Using Martyte ....................................................... 33
Figure 33 . Side Flame Duct at LC 17B ............................................................................. 34
Figure 34. Concrete Tunnel Adjacent to LC 17B .......... .... ... ................... ......................... 35
Figure 35. Damage to Side Flame Tunnel Support Columns ............................................ 35
Figure 36. Enclosed Flame Trench at LC 17B .................................................................. 36
Figure 37. Abrasion to the Interior Surface of Main Flame Trench Walls ....................... 36
Figure 38. Flame Duct at LC 17B ..................................................................................... 37
Figure 39. Martyte Patch on Flame Deflector Side Wa11 ......................... ........................ .37
Figure 40. Martyte on Water Deluge System .................................................................... 38

VI
 NASA/TM-20 13-217910

Figure 41. Martyte-Protected Bolt Heads .......................................................................... 38

Figure 42. LC 17B Launch Deck ..................................... ... .............................................. 39
Figure 43 . LC 17B Exhaust Port on Launch Deck ............................................................ 39
Figure 44. Ablative Coating on Tubing in Center of LC 17B Launch Deck ................... .40
Figure 45. LC 34 Flame Deflector and Launch Pad ........................................................ .41
Figure 46. Flame Deflector at LC 34 on December 11 , 2008 .......................................... .41
Figure 47. Refractory Material at LC 34 .......................................................................... .42
Figure 48. Delta IV Heavy at Launch Complex 37 ......................................................... .43
Figure 49. LC 6 at Vandenberg Air Force Base .................................................. ............. .47
Figure 50. Palm Beach County Fire Rescue Training Facility ............................... ......... ..48
Figure 51. System 203 Tiles at the Palm Beach County Fire Training Center ................ .49
Figure 52. Interlocking System 203 Tiles ................................................ ......................... 50

Tables

Table 1. Corrosion Rates of Carbon Steel Calibrating Specimens at Various

Locations ... ......... ......................... ....................................................................... 3

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NASA/TM-20 13-217910

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 NASA!TM-2013-217910

Abbreviations, Acronyms, and Symbols

oF degree Fahrenheit
AFB Air Force Base
AFSPC Air Force Space Command
CCAFS Cape Canaveral Air Force Station
CRS Cargo Resupply Services
CxP Constellation Program
EELV Evolved Expendable Launch Vehicle
ELV Expendable Launch Vehicle
ETDP Exploration Technology Development Program
FOD foreign objects and debris
FSS Fixed Service Structure
tf square foot
FUT Fixed Umbilical Tower
GHz gaseous hydrogen
GHe gaseous helium
GNz gaseous nitrogen
GOz gaseous oxygen
GOP Ground Operations Project
gpm gallon per minute
GSE ground support equipment
IRBM intermediate-range ballistic missile
JPL Jet Propulsion Laboratory
KSC Kennedy Space Center
lb pound
LC Launch Complex
LHz liquid hydrogen
LOX liquid oxygen
MLP Mobile Launch Platform
MST Mobile Support Tower
NASA National Aeronautics and Space Administration
pst pound per square inch
RSS Rotating Service Structure
SRB solid rocket booster
sse Stennis Space Center
STS Space Transportation System
UT Umbilical Tower

IX
NASA/TM-20 13-217910

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 NASA!fM-2013-217910

1 INTRODUCTION

During the Technology Prioritization Panel held in December 2007, the Constellation Program
(CxP) Ground Operations Project (GOP) identified corrosion control technologies as their #2
technology need for initial capability to meet Draft Stretch/Operability requirements for reduced
ground processing complexity, streamlined integrated testing, and operations phase affordability.

The Refractory Materials for Flame Deflector Protection System Corrosion Control task under
the Supportability project will develop refractory technologies that will provide support at
Kennedy Space Center (KSC) launch facilities and ground systems through increased operational
life cycles.

As a result of the constant deterioration from launch heat/blast effects and aggressive
environmental exposure, the refractory materials currently used as a part of the launch pad flame
deflectors have become very susceptible to failure, resulting in large pieces of refractory
materials breaking away from the steel base structure. These pieces are projected at high speed
during launch, and jeopardize the launch complex, vehicle, and safety of the crew.

Replacement refractory systems must be developed to withstand the extremely corrosive

environment at the launch pads, and the highly corrosive hydrochloric acid and heat/blast effects
that are generated by the solid rocket boosters during a launch. Advanced technologies for the
corrosion protection of launch pad flame deflectors are necessary to address these problems and
significantly impact ground processing and launch safety.

1.1 Objectives of the Exploration Technology Development Program (ETDP) Refractory

Studies

The objective of the ETDP project, Refractory Materials for Flame Deflector Protection System
Corrosion Control is to develop replacement refractory materials that exhibit long-term
resistance to degradation. This degradation results from the extremely corrosive Florida coastal
environment and aggressive launch conditions. The highly corrosive solid rocket booster (SRB)
exhaust, extreme temperature fluctuations between SRB heat impingement and noise suppression
water deluge, and SRB blast vibrations, in combination, have a pronounced detrimental influence
on the degradation of refractory materials.

The flame deflector must safely divert flames, exhaust, and small items that are loosened during
a launch. In essence, the system must prevent debris from bouncing back and hitting the launch
complex and vehicle. Performance in this regard is dependent upon integrity of the refractory
materials used on the flame deflectors.

The development process for the ETDP Refractory Materials for Flame Deflector Protection
System Corrosion Control project has four primary elements.
NASA/TM-20 13-217910

• Capability to develop a refractory protection system for the launch pad flame
deflectors.
o Long term corrosion protection
o Mitigate the safety risk caused by frequent failures and unacceptable
performance (cracking and spalling during launch) of the current refractory
concrete materials.
o Mitigate the risk of frequent, expensive, and extensive repairs that with the
current material, also provide unacceptable performance.
• Capability to develop advanced refractory materials.
o That provides acceptable performance and maintain their integrity during/after
exposure to the launch environment (high temperature exhaust impingement,
blast loading, water deluge delta temperature, and acoustic loading) without
cracking or spalling.
o That can resist the degradation of thermal-protection characteristics caused by
seacoast exposure.
• Capability to develop material requirements, system specifications, and qualification
standards for the refractory material protection system.
• Capability to incorporate the refractory material formulation onto the flame deflector
base structure, and evaluate the in-situ performance in an integrated demonstration
on a scaled, simulated flame deflector.

Knowledge gained from the development of refractory material systems for flame deflectors will
be leveraged to evaluate materials and systems for the replacement of refractory fir~bricks along
the flame trench vertical walls.

1.2 Current Task

The current task consists of a report on a trade study that investigates refractory materials used in
similar industries that would provide a direct benefit to KSC launch pad flame deflectors.
Understandably, the environment that refractory materials are subject to (under launch) are
extreme, and consequently, this investigation is oriented toward materials that are subject to high
temperatures, extreme temperature fluctuations, significant erosion and ablation, water
infiltration and acidity from the solid rocket boosters.

Site and literature investigations, as well as interviews with key refractory and launch personnel
were conducted to ascertain the refractory and ablative materials that are used in these extreme
environments. This report summarizes the refractory and ablative materials that are used at other
launch locations and facilities that are similar to the environments NASA's launch complexes.

1.3 Launch Environment

The launch facilities at KSC are approximately 1000 feet from the Atlantic Ocean. The seacoast
marine location is extremely corrosive to structural steel. In fact, the beachside location at KSC
is documented as one of the most corrosive environments in the world. Table 1 shows the
corrosion rates for the KSC Beachside Exposure Corrosion Test Site. The corrosion rates in the
table clearly show the aggressiveness of the KSC locale, in relation to the others that are listed.

2
 NASA!I'M-20 13-217910

Table 1. Corrosion Rates of Carbon Steel Calibrating Specimens

at Various Locations 1

Loc:atioa T;me o1Ea1'iroa•eat ~!;tr •ib/yr

Esquimalt, Vaneouver Island, Rural marine 13 0.5
BC, Cmada
Pittstugb. PA Industrial 30 1.2
C1evdand, OH Industrial 38 u
Limon Bay, Panama Tropical marine 61 2.
East Chicago, n. Industrial 84 3.3
Brazos River, TX Indusnal marine 94 3.7
DaytcmaBeac:h, R Marine 29~ 11.6
Pont Reyas, CA Marine ~00 19.7
Kwe Beacb. NC (24 m from Marine ~33 21
ocean)
GII eta Point Beach, Panama Marine 686 27
Keaaely S,ace Ceattr, FL Mari:ae 1070 42
(Beula}

KSC launch facilities and ground support equipment (GSE) are exposed to extremely corrosive
marine conditions. As if those conditions were not bad enough, in 1981 , the Space Shuttle
introduced a more aggressive environment to the launch pads at KSC . Exhaust from the SRBs
resulted in the deposition of small alumina particles with hydrochloric acid adsorbed onto their
surface. It is estimated that 70 tons of hydrochloric acid are generated during a Space Shuttle
launch. The impingement of this acidic exhaust results in the failure of refractory materials,
despite the fact that a pressure wash-down is performed immediately after launch.

In response to the SRB exhaust problem, studies were conducted at KSC to increase the chemical
resistance of protective coatings and materials in response to this more aggressive propulsion
system. 2,3,4,5,b,7,s

1
Coburn, S., "Atmospheric Corrosion," in American Society for Metals, Metals Handbook, Properties and
Selection, Carbon Steels, Metals Park, Ohio, 9th ed., Vol. I, p.720, 1978.
2
Ruggieri, D. and Rowe, Anne, "Evaluation of Carbon Steel, Aluminum Alloy, and Stainless Steel Protective
Coating Systems After 18 Months of Seacoast Exposure," NASA Technical Memorandum I 03503, May 1984.
3
MacDowell, L.G., "Evaluation of Protective Coating Systems for Carbon Steel Exposed to Simulated SRB
Effluent after 18 months of Seacoast Exposure," NASA Report No. MTB-268-86B, February 1988.
4
MacDowell, L.G., "Volatile Organic Content (VOC) Compliant Coating Systems for Carbon Steel Exposed to the
STS Launch Environment - Application, Laboratory and 18 Month Exposure Results," NASA Report
No. F AM-93 -2004, February 23 , 1993.
5
MacDowell, L.G., "Testing VOC-Compliant Coating Systems at Kennedy Space Center, Materials Performance,"
32,p.26-33, 1993.
6
Calle, L.M., and MacDowell, L.G. , "Improved Accelerated corrosion Testing of Zinc-Rich Primers," NASA Tech
Briefs, 24, p. 78, 2000.
7
Calle, L.M., and MacDowell, L.G., "Evaluation oflnorganic Zinc-Rich Primers Using Electrochemical Impedance
Spectroscopy (EIS) in Combination with Atmospheric Exposure," in proceedings ofNACE International
Conference on Corrosion in Natural and Industrial Environments: Problems and Solutions, Grado (Gorizia), Italy
May 23- 25 , 1995.

3
NASA/TM-2013-217910

2 ASSETS EVALUATED IN THIS ANALYSIS

KSC launch operations consist of seven major structures that include two launch complexes,
three Mobile Launch Platforms (MLPs), and two Mobile Crawlers. Collectively, these assets
consist of 5,443,696 ff of structural steel. 9 Refractory materials were developed and integrated
as components to protect these assets from the repeated rocket blast and high temperatures that
are exhibited during launch.

Refractory degradation is not limited to the launch complexes at KSC. Consequently, the
development of new refractory products will prove beneficial, not only for assets under
investigation as a part of the refractory project, but also for assets at other centers. In a similar
fashion, the beneficial attributes of new refractory systems can be extrapolated to other
government entities and to private industry.

Two complexes support mobile launch operations and are available for the Space Shuttle.
Launch Complex (LC) 39A and LC 39B are sisters of each other, and share similar
characteristics. The launch complex can be tentatively delineated by four sections (Figure 1).
The flame deflector, which is the subject of this report, is a subcomponent under pad structures.
The four sections include the: 10

a. Fixed Service Structure (FSS)

b. Rotating Service Structure (RSS)

c. Perimeter

d. Pad Structures

8
Calle, L.M., and MacDowell, L.G., "Evaluation oflnorganic Zinc-Rich Primers Using Electrochemical Impedance
Spectroscopy (EIS) in Combination with Atmospheric Exposure," NASA Report No . 94-2082, John F. Kennedy
Space Center, Florida, April 17, 1995.
9
NASA NE-M9, "KSC Corrosion Control Overview for Stennis Space Center," March 13, 2008.
10
Launch Complex 39, Pads A and B, www.nasa.gov/pdf/168440main LC39-06.pdf. Last accessed on
April 7, 2008.

4
 NASAffM-2013-217910

Figure 1. KSC Launch Complex 39B

The FSS and MLPs were originally designed for a 20-year lifespan with the Apollo era vehicles
that used liquid propellants. Even after 40 years of service, the structures remain in use with the
Space Shuttle and its deleterious solid rocket boosters. 11

The FSS has three swing arms that provide services and access to the Space Shuttle prior to
launch. The Orbiter Access Arm is a component of the FSS that allows personnel to enter the
Shuttle crew compartment, and serves as an escape route for the astronauts prior to launch.

The External Tank Hydrogen Vent Umbilical and Intertank Access Arm on the FSS support
tanking, and the External Tank Gaseous Oxygen Vent Arm allows for the transfer of heated
gaseous nitrogen to warm the liquid oxygen vent system on top of the external tank. This
prevents the buildup of ice, which could have damaging consequences to the Shuttle during
launch.

The FSS also contains the Emergency Egress System, which includes seven baskets for the
emergency evacuation of the launch complex by the astronauts.

11
Personal communication with Harry Moore, United Space Alliance. April I 0, 2008.

5
NASA/TM-20 13-217910

The RSS provides a means to install and service Space Shuttle payloads while at the pad.
Furthermore, this structure· supports servicing operations on the Space Shuttle that cannot be
performed from the FSS.

The perimeter of the launch pad is the area inside the fence but beyond the pad surface. It
includes the liquid oxygen (LOX) and liquid hydrogen (LH 2 ) storage tanks, as well as pipes,
tanks and small buildings. The LOX and LH2 tanks contain and deliver the fuels to the Space
Shuttle's external tank prior to launch.

Launch pad surface structures typically include the MLP holddown posts, the MLP access
towers, the hydraulic elevator and the flame deflector.

Figure 2 shows the Space Shuttle launches by pad for each year since the inception of the Shuttle
program in 1981. The data proved useful since it helped delineate years when launch pads were
not in use, and others when they were used much more extensively. This data can be correlated
to times in which more frequent repair to the refractory systems was required. Furthermore, the
frequency of launch can be compared to other launch sites.

6
 NASA/TM-2013-217910

Shuttle Launches (1981-2008)

6
., Chalenger
Tragedy
Coluntia
Tragedy
.! 5
~
...."'
..•
..
0

.a
4

! 3
z
2

§;~;~~;;~~;~;;~~~;~~;~~~~,,~
Yur

Figure 2. Space Shuttle Launches by Year and Complex

7
NASA/TM-20 13-217910

The first Shuttle launch on April 12, 1981, resulted in a few unexpected problems. For example,
an anticipated pulse pressure of 0.5 pound per square inch (psi) was actually 2.0 psi when the
two SRBs ignited. The redesign of the flame deflector was one of the potential resolutions to the
problem. However, a new water suppression system was implemented to address the pressure
problem. 12

Figure 3 shows a schematic of the flame deflector at LC 39. LC 39A and LC 39B were originally
designed to support the Apollo program. With the advent of the Shuttle program, the Saturn-era
flame deflectors were replaced. The orbiter side of the new flame deflectors are 38ft high, 72ft
long, and 57ft wide. The SRB side of the flame deflector is 42ft high, 42ft long, and 57ft wide.
The total mass of the asset is over I mi Ilion pounds. 13

The flames from the main engines and the SRBs are channeled down opposite sides of the flame
deflector. The deflector is made of steel on a structural steel !-beam framework. To protect the
structure from serious degradation during launch, the faces of the flame deflector are lined with
refractory concrete. This product is known as Fondu Fyre W A-1 G supplied by the Pryor Giggey
Co.

flames hmorbiter's
main erwmes J
North

Figure 3. Cross Section of Flame Deflector at Launch Complex 39A

Figure 4 shows the configuration of the Shuttle viewed upward from the floor of the flame
trench. The openings for the Space Shuttle exhaust and the flame deflector, which is used to
divert the rocket plume from the SRBs, are labeled. The other side of the flame deflector, which
is not visible in the picture, is for exhaust from the main engines. The SRBs burn at
approximately 3000 degrees Fahrenheit (°F), while the exhaust from the main engines burn at a
lower temperature. Consequently, the higher temperatures of the SRB exhaust lead to more
severe exposure conditions and result in damage that is more significant to the deflector.

12
Kolcum, Edward H., "NASA Studying Pressure Problem in Space Shuttle," Aviation Week & Space Technology ,
July 6, 1981 , p.21.
13
http://science.ksc.nasa.gov/facilitiesllc39a.html. Last accessed on December 17, 2008.

8
 NASA!TM-2013-217910

Figure 4. Openings for Flames From the Main Engine and SRBs

Figure 5 shows a magnified view of the flame deflector underneath the SRBs. The bottom of the
deflector shows the structural steel, which is protected with Fondu Fyre at a depth of
approximately 6 inches.

The ability of the flame deflector to safely meet the requirements of diverting the flame, exhaust,
and small items that are dislodged during launch is dependent on the integrity and performance
of the refractory materials. Consequently, the use of refractory products that have superior
material characteristics (under launch conditions) is required to protect the flame deflector,
Space Shuttle, GSE, and launch personnel.

9
NASA/TM-20 13-217910

Figure 5. Magnified View of LC 39A Flame Deflector

3 DETERIORATION AND REPAIR OF REFRACTORY MATERIAL USED AT

LC 39A AND LC 39B

The launch complexes at KSC are critical support facilities that are required for the successful
launch of space-based vehicles. Most of these facilities are over 25 years old, and consequently,
are experiencing deterioration. As a result of the constant deterioration from launch heat/blast
effects and environmental exposure, the refractory materials used at LC 39A and LC 39B have
become susceptible to failure, resulting in large sections of refractory material breaking away
from the base structure and creating high-speed projectiles during launch. These projectiles
jeopardize the safety of the launch complex, crew, and vehicle. Postlaunch inspections have
revealed that the number and frequency of repairs, as well as the area and size of the damage, is
increasing with the number of launches.

It is assumed that the composition ofFondu Fyre may have changed. This conclusion is based
upon the change in color of the product.

Refractory concrete protects launch structures from elevated temperatures. These materials
utilize hydraulic cement as a binding agent. The refractory material used at LC 39A and LC 39B
is Fondu Fyre W A-1 G supplied by the Pryor Giggey Co. The product was developed in the
1960s solely for the National Aeronautics and Space Administration (NASA) and is the only
product qualified for use at LC 39A and LC 39B.

10
 NASA!fM-20 13-217910

During the selection of the material, the acidic exhaust of the SRBs and the temperature
fluctuations that result from the sound suppressing water deluge were not considered. An
analysis of test data taken from 1981 to 1993 indicates that this refractory material does not meet
the requirements ofKSC-SPEC-P-0012, Specification for Refractory Concrete (1979). In fact,
testing during this period indicated that none of the submitted refractory products could meet the
required specifications. As such, the only qualified material for use at KSC does not meet the
required specifications. Review of the current specification and testing requirements indicate that
the test methods and qualification criteria are not well defined. Other, possibly better-performing
materials have not been qualified because of the poorly defmed specification tests and
requirements. 14

Failure to meet these standards increases the likelihood that the product will prematurely
degrade. This has resulted in cracking of the product, corrosion of the metallic anchoring
structure (grid steel and Nelson Ties), spalling, and liberation of the refractory concrete during
launch.

Figure 6 shows a section ofFondu Fyre WA-lG refractory concrete that spalled on the main
engine side of the flame deflector LC 39A during the launch ofSTS-126 (November 14, 2008).
This section dislodged during launch and was subsequently hurtled downrange.

Figure 6. Evidence That a Section of Concrete Was Dislodged

During the Launch of STS-126

The anomaly may have resulted from the seepage of water through the cracked refractory
concrete. This resulted in corrosion to the grid steel, which reduced the adhesion between the
refractory and base material. During launch, the water under the concrete section may have
turned to steam, further lifting the section from the surface. The thrust from the Space Shuttle
main engines hurled the object downrange.

14
Calle, L.M., Trejo, D. , and Rutkowsky, J. , "Evaluation of Alternative Refractory Materials for the Main Flame
Deflectors at KSC Launch Complexes," NASA TM-2006-214197, March 2006.

11
NASA/TM-2013-217910

After the launch of STS-126, the section of refractory concrete was located halfway down the
length of the flame trench. A picture of the dislocated concrete section is shown in Figure 7.

Figure 7. Section of Concrete That was Dislodged During the Launch of STS-126

Advanced technologies for material protection are required to address problems that impact
ground processing and launch safety. The ability of the flame deflector to meet the requirements
of diverting the flames, exhaust, and loosened items during launch is critical. The flame deflector
must prevent foreign objects and debris (FOD) from deflecting off surfaces and possibly hitting
the launch complex and vehicle.

NASA has plans to update LC 39A and LC 39B for the future Ares vehicles. Modifications to
the facilities will require reconditioning of the currently used flame deflectors. Ideally,
refurbishment will be performed with refractoR' materials that will extend the useful life of the
structure for an additional 40 years of service. 1

Plans to mount the Ares rocket over the left SRB hole are being considered, and there are
concerns related to thrust pressure blowing through the two unused holes (i .e., the right SRB hole
and the hole for the main engine). Flame trench pressurization data (from the first Shuttle
mission) prior to the implementation of the water suppression system, as compared to data after
the water deluge was implemented, predicts that the current flame deflector configuration would
not have a pressure increase greater than 2 psi. 16

15
Coppinger, R. , "Ares 1-1 pad 39B to be modified," Flight International, February 6, 2007.
16
Mecham, M., "Screen Savior," Aviation Week & Space Technology, Vol. 169, No. 7, p. 87, August 18, 2008.

12
 NASA!fM-2013-217910

4 GENERAL CATEGORIES OF REFRACTORY MATERIALS FOR LAUNCH

APPLICATIONS

4.1 Firebrick

Firebrick is a refractory product that is kiln baked prior to placement. Firebrick contains up to
44% alumina, is dense, and melts at high temperatures. 17 A thorough discussion regarding the
material characteristics of firebrick is beyond the scope of this report, though it should be
emphasized that the material has been used throughout NASA launch history.

Historical remnants of firebricks can be found at the abandoned LC 34 at KSC (Figure 8). As
shown in the figure, the firebricks were produced by the A.P. Green Company. The date of
manufacture is the mid to late 1950s.

Figure 8. Firebricks at the Base of Launch Complex 34

While the design of LC 34 necessitated the use of a flame deflector, refractory firebrick was used
in non-impingement, elevated temperature areas at the base of the launch structure. The rails
shown in Figure 9 were used to transport the flame duct to and from the facility. During launch,
the blast was directed to the fore and aft orientation in Figure 9. Consequently, refractory
firebrick was designated for these locations. In contrast, normal construction grade concrete was
used at the sides.

17
Lee, C.C., and Dar Lin, S. , Handbook of Environmental Engineering Calculations, McGraw-Hill, 2000. Online
version available at
http://knovel.com/web/portal/browse/display? EXT KNOVEL DISPLAY bookid=621 &VerticaliD=O

13
NASA/TM-20 13-217910

Figure 9. Firebrick at Launch Complex 34

The use of refractory firebrick for launch pad applications has continued through the Shuttle era.
As shown in Figure 10, firebrick was designed into the floors and walls ofthe flame trench at the
Shuttle launch pads.

On May 31, 2008, serious damage to the walls of the flame trench occurred during the launch of
the Space Shuttle Discovery (STS-124). Blast from the SRBs resulted in the expulsion of over
500 firebricks from the flame trench walls (Figure 10). The interlocking firebricks measured 6 by
3 by 13.5 inches and were attached to the 3-foot-thick concrete substructure with epoxy and
metal clips. The clips, anchored in concrete, are horizontally attached to every other brick, and
vertically at every sixth row.

Figure 10. Damaged Walls at LC 39A

14
 NASA/TM-2013-217910

While precast firebricks have improved material characteristics, the placement of the individual
pieces into a fully operational design can be complex. Furthermore, structural repair and
replacement is cost-prohibitive given the labor costs associated with skilled bricklayers who are
required for the appropriate installation of the product. Consequently, while the refractory
firebrick provides improved material properties, the cost of the product and labor for installation
are much higher than that required for the installation of traditional refractory concrete. 18

4.2 Refractory Concrete

The selection of refractory concrete materials for flame deflectors requires products that are
resistant to thermal shock, provide strength at high temperature, have limited changes in
dimension at very high temperature, are spall resistant, resists crack propagation, are resistant to
acoustic shock, have insulating properties (steel reinforcement will expand and crack refractory
material), and can be cured by normal procedures without cracking. 19 Furthermore, manufactures
formulate refractory products so that they can be applied by the Gunite process. Consequently,
the product can be placed with little effort as compared to that necessary with the placement of
firebrick.

The use of calcium aluminate aggregates, in conjunction with the calcium aluminate cement,
produces a hardened concrete that is resistant to the deleterious effects of high temperature
environments. When the calcium aluminate aggregate is employed, the shotcrete system is a
high-strength product that provides outstanding resistance to heat and thermal shock (to
2000 °F), and very good abrasion resistance.

Calcium aluminate concrete products are used as linings in fire training structures and have been
employed in sulphur pit applications in petrochemical industries. Direct contact with molten
sulfur produces an extremely corrosive environment at moderately high temperatures. 20 This
environment would severely damage structures erected using construction grade Portland
Cement containing concrete.

Calcium aluminate cement is used as a binder for refractory concretes that are used in launch
environments. Often, the product is used in direct flame impingement areas that include the
flame deflectors and exhaust tunnels. Both areas are subject to very high temperatures and
abrasion from solid airborne particulates. The calcium aluminate products are extensively used at
KSC, Stennis, and Vandenberg Air force Base. The formulation of the concrete mixes can differ
between manufacturers.

Typical refractory concretes include Fondu Fyre, which is used for the Space Shuttle at LC 39A
and LC 39B, as well as Fondag which is used in other areas ofKSC and Vandenberg. Both
products use calcium aluminate cement as a binder. Crushed firebrick is added to Fondu Fyre to

18
Telephone interview with Doug Goddard, Atlantic Firebrick, January 6, 2009.
19
Lays, E.J. , and Darrow, E.A., "Effects of Exhausts from Aluminized Solid Propellants on Launch Facilities," J.
Sfacecraft, Vol. 4, No.7, 934-940, July 1967.
2
Fitzgerald, M.W., Talley, J. , and Alt, C.W. , "Calcium Aluminate Technology and Its Application in Refractory
Concrete," Shotcrete, Summer 2002.

15
NASA/TM-20 13-217910

produce the concrete mix, while Fondag uses a calcium aluminate aggregate.21 Both products
were prevalent at the launch sites visited, and can be applied using the Gunite process.

Refractory materials for launch applications have unique material requirement such as thermal
shock, abrasion, and erosion resistance. Consequently, various materials have been tested under
simulated launch conditions. Some ofthese materials include Fondu Fyre WA-1, Fondu Fyre
XB-1, Fondag DG, Harbison-Walker Harcast ES, and Harbison-Walker 13-65 Fused Silica
Castable Mix. 22 ' 23

As discussed in later sections of this report, the gunnable formulation ofFondu Fyre (Fondu Fyre
W A-1 G) and the Kemeos refractory (Fondag DG) were predominantly seen at the launch sites
inspected as a part of this report.

4.3 Epoxy and Silicone Ablatives

Protective coatings have been formulated to protect metal structures that are not subject to direct
rocket motor blast. Development criteria necessitated that they were easy to apply, adhered well
to the underlying substrate, had high resistance to thermal and acoustic shock, and provided
erosion and ablation limiting characteristics. Furthermore, the coatings had to be compatible with
exhaust residue from the motors, as well as the liquid propellants that are used for launch and
vehicle operations. These include LOX and the hypergol propellants.

The two classes of materials that have been considered for these applications include the epoxies
and silicones.

Off-the-shelfthermal protective coatings of this type have been evaluated for peripheral launch
pad applications. They include, but are not limited to, Dynatherm E-300, Dow Coming Q90-006,
Dow Coming Q20-l 03, Dow Coming Q30-121 , Dow Coming Q93-0 19; Fuller Fulblate 878
Types I and II, Fuller 190J-4, Korblate ll-190:L, General Electric RTV 511 and RTV 757
(foamed); and Raytheon RPR 2138, RPR 2141, RPR 2156, and General Electric CPC-1050 and
SCM 3404. 24 ' 25

While most products in this category were originally designed for use outside direct blast areas,
others have been developed for the more aggressive exposure. These products include Martyte
and Havaflex T A II 7.

21
Telephone interview with Greg Wallace, Kemeos Aluminate Technologies, January 6, 2009.
22
Lays, E.J., and Darrow, E.A., "Effects of Exhausts from Aluminized Solid Propellants on Launch Facilities,"
J. Spacecraft, Vol. 4, No . 7, 934- 940, July 1967.
23
Douglas, F.D., Dawson, M.C. , and Orlin, P.A. , "ASRM Subscale Plume Deflector Testing," AIAA 92-3919,
AIAA 17th Aerospace Ground Testing Conference, Nashville, Tennessee, July 6-8, 1992.
24
Lays, E.J., and Darrow, E.A. , "Effects of Exhausts from Aluminized Solid Propellants on Launch Facilities,"
J. Spacecraft, Vol. 4, No. 7, 934- 940, July 1967.
25
Sprayable Silicone Ablative Coating, GE Product Code CPC-1 050, Post Launch Evaluation on Launch
Complex 40, Cape Canaveral Air Force Station, NASA Failure Analysis and Materials Evaluation Branch;
Report 92-2150, November 23, 1992.

16
 NASAffM-20 13-217910

Martyte has been evaluated as a protective coating for metal surfaces. 26 Martyte is a ceramic
filled, amine-cured epoxy compound that was originally developed by Martin Marietta. Site
visits revealed that the material was often used on top of construction grade concrete, refractory
concrete, and structural steel. Use of this material is described later in this document.

Havaflex T A 117 is a two-component modified phenolic ablative coating and adhesive that was
originally developed for the U.S. Navy. The product can be troweled or sprayed, and was
designed to protect decks, bulkheads, and shipboard launching systems from the extremely high
temperatures (up to 5000 °F.) and high gas velocities that are present during launch operations. 27

5 MATERIAL INVESTIGATIONS BY SITE

A literature survey and site visits were conducted to determine which refractory materials were
used in industries similar to NASA's launch environments.

This section summarizes the results from these investigations.

5.1 Stennis Space Center

Stennis Space Center (SSC) is located in Hancock County, Mississippi, at the Mississippi-
Louisiana border (Figure 11). Stennis is NASA's largest rocket engine test facility.

Construction of the 13,500-acre complex began in October 1961. The test area is surrounded by
a 125,000-acre acoustical buffer zone. The facility's large concrete and metal test stands were
originally used to test-fire the first and second stages of the Saturn V rockets and are now used to
flight certify the Space Shuttle main engines.

The site was originally selected by the U.S. government because it was located in a thinly
populated area that had barge access. Furthermore, the site is advantageously located between
the Michoud Assembly Facility and the launch facility in Cape Canaveral in Florida.

26
Lays, E.J., and Darrow, E.A. , "Effects of Exhausts from Aluminized Solid Propellants on Launch Facilities,"
J. Spacecraft, Vol. 4, No. 7, 934- 940, July 1967.
27
Havaflex T.A.-117, A Trowelable Ablative Material. http://new.ametek.com/content-
manager/files/HAV//Havaflex l .pdf. Last accessed on January 9, 2008.

17
NASA/TM-2013-217910

Figure 11. Stennis Space Center Location

5.1.1 A-2 Test Stand

The A-2 Test Stand is a single-position, vertical firing fixture that can accommodate test articles
up to 33ft in diameter. An exterior view of the test complex is shown in Figure 12.

Figure 12. Exterior View of the A-2 Test Stand

The test facility is designed to use LH 2 and LOX propellants and can accommodate support
fluids , which include gaseous helium (GHe), gaseous hydrogen (GH 2) , and gaseous nitrogen
(GN 2). It is equipped with an altitude diffuser, which is utilized to simulate altitude conditions

18
 NASAffM-2013-217910

during engine testing. The maximum dynamic load that the structure is capable of testing is
1.1 million foot pounds. 28

Figure 13 shows the relative size of the flame deflector in relation to members of the refractory
site review team.

Figure 13. View of the A-2 Flame Duct and Diffuser

The A-2 Test Stand is fabricated from steel and uses water for cooling. Prior to a test, the interior
cavity of the flame deflector is filled with water. Thirty minutes before the test, the pipes and
manifolds are filled at a rate of3000 gallons per minute (gpm). Six minutes prior to the test,
large pumps increase the flow rate to 160,000 gpm. This produces approximately 225 psi of
water pressure.

During the test, water exits from the holes in the surface of the deflector to reduce temperature
effects that are induced by the rocket exhaust (Figure 14). Each hole is 5/32 inches in diameter,
flows 7 gpm, and is drilled so that there are 14 holes per square foot, in the lower "hot" area.
Fewer holes are present on the sides and away from the plume impact. 29 The perforations are
also advantageous since they may reduce stress that can warp the metal deflector. 30

28
A-2 Test Stand. http://sscfreedom.ssc.nasa.gov/esd!ESDTestfacilitiesA2.asp. Last accessed on
November 7, 2008.
29
E-mail correspondence with Nickey Raines, Stennis Space Center, January 14, 2009.
30
Personal interview with Dr. Charles E. Semler, Semler Material Services, December I, 2008.

19
NASA/TM-20 13-217910

Figure 14. Holes Drilled Into the Surface of the Steel A-2 Test Stand

In general, some kind of thermal protection is required to reduce thermal stress and buckling of
the flame deflector. 31 Early work on deflector design for SRBs, indicated that metallic structures
were only feasible if the steel structure remained at least 1.5 nozzle exit diameters laterally from
the exhaust plume and provided the vehicle exits from the launch pad surface by at least
50 nozzle diameters in less than 10 seconds. 32

5.1.2 B-1 and B-2 Test Stands

Each B-1 and B-2 Test Complex consists of a dual-position, vertical, static-firing test stand. The
B Complex is 295 ft tall and is equipped with a 200-ton main derrick-lifting crane. The test stand
was designed to use LH 2 and LOX propellants, and can accommodate various support fluids that
include GHe, GH 2, and GN 2 • The maximum dynamic load that each structure is capable of
testing is 11 million foot pounds. 33

The refractory material team from KSC intended to inspect one of the test stands. Unfortunately,
a direct inspection at that time was impossible since the area was cleared for a test. The rocket
test is shown in Figure 15.

31
Design Handbook for Protection of Launch Complexes from Solid Rocket Propellant; Report
No. Martin-CR-66-11 ; Martin Marietta; March 1966.
32
A Brief Study of Flame Deflection, Report 1323, Aerojet General, August 1957.
33
B-1 Test Stand. http://sscfreedom.ssc.nasa.gov/esd/ESDTestFacilitiesB I. asp . Last accessed on November 7, 2008.

20
 NASA!fM-2013-217910

Figure 15. Rocket Motor Test at Stennis B-1 Complex

As a part of a prior project, NASA Corrosion Laboratory personnel photo-documented the B-2
Test Stand flame deflector (Figure 16).

Similar to the A-2 Test Stand discussed in 5.1.1, the B-2 test stand is a steel structure that is
much larger in scale. Figure 16 is used to give a comparative size of the B-2 flame duct in
relation to others that are discussed in this report. To cool the flame deflector, the deluge system
supplies 333,850 gpm of high-pressure industrial water for an extended period at a pressure of
225 psi. 34

34
Fisher, M.F., and King, R.F., "Low-Cost Propulsion Technology Testing at the Stennis Space Center-Propulsion
Test Article and the Horizontal Test Facility," AIAA-98-3367 , 34th AIAA/ASME/SAE/ASEE Joint Propulsion
Conference and Exhibit, Cleveland, Ohio, July 13- 15, 1998.

21
NASNTM- 2013-217910

Figure 16. Stennis B-2 Flame Deflector

The design of the B-2 Test stand was similar to the A-2 test stand previously discussed, as both
had holes perforated in the surface of the deflector. The utility of these holes was discussed in
Section 5.1.1. Particular mention is made of corrosion in areas adjacent to the B-2 Test stand
drain holes (Figure 17).

Corrosion near the drain holes is a particularly important observation with regard to the design of
flame deflectors. Flame deflectors that are used for corrosive SRBs in a coastal environment
(such as KSC) may suffer from much greater corrosion problems than those seen (Figure 17) at
Stennis Space Center, due to the acidic conditions and proximity to the seacoast.

Figure 17. Drain Holes at the Base of the B-2 Flame Deflector

22
 NASAffM-2013-217910

5.1.3 E-2 Test Facility

The E-2 Test Facility was constructed to support materials development by subjecting test
articles (including refractory concrete) to extreme temperature conditions and fluctuations. This
facility has support capabilities, which include hot gas, cryogenic fluids, gas impingement, inert
gases, industrial gases, specialized gases, hydraulics, and water.

The E-2 facility is a multi-cell complex that is capable of testing intermediate size engines in
both the vertical and horizontal configurations.

E-2 Cell 1 (Figure 18) is the horizontal test cell, and utilizes propellants such as LOX, LH 2, and
RP-1. The horizontal testcell is capable oftesting motors with thrust loads up to 120,000 foot
pounds. 35 Cell 2 is the vertical test cell, and utilizes LOX and RP-1 fropellants. This test cell is
capable of testing motors with up to 100,000 foot pounds ofthrust. 3

Figure 18. E-2 Cell 1 Test Stand at Stennis Space Center

Figure 19 shows an overview of the Cell 2 flame duct. As shown in the photo, the flame
deflector was built from steel over anI-beam steel structure. The facility has a 4000 gpm water
deluge system that is used to protect the flame duct from plume radiant heating during testing.37

35
Test Facilities Capability Handbook, Stennis Space Center, NP-200 1-11-00021-SSC, November 200 I .
36
E-2 Test Facility. http://sscfreedom.ssc.nasa.gov/esd!ESDTestFacilitiesE2.asp. Last accessed on
November 7, 2008.
37
Test Facilities Capability Handbook; Stennis Space Center; NP-2001-11-00021-SSC; November 2001.

23
NASA/TM-20 13- 217910

Figure 19. Stennis Space Center E-2 Cell 2 Vertical Test Flame Duct

The depth of the refractory concrete used to protect the underlying steel varied. The average
depth of the refractory layer was approximately two inches at the center. In contrast, the depth of
the refractory material at the walls was approximated at only 1 inch in depth.

Figure 20 shows the floor and wall of the Stennis E-2 Cell2 flame deflector. Site personnel were
unable to determine the vendor or product identity of the refractory concrete used in this flame
deflector.

Figure 20. Refractory Concrete on Walls and Floor of

Stennis E-2 Cell 2 Flame Deflector

24
 NASA/TM-20 13-217910

5.1.4 E-3 Test Facility

The E-3 horizontal test cell can test motors up to 60 thousand foot pounds of thrust, and has
support capabilities that include LOX, gaseous oxygen (G0 2 ), and GH 2 • Cell 2 is a vertical test
cell that is capable of testing engines that use LOX, hydrogen peroxide and HC propellants.
Cell2 can accommodate engines with thrust loads up to 25,000 foot pounds ofthrust. 38

Figure 21 shows the flame duct for the vertical E-3 Cell 2 test fixture. Numerous tests have been
conducted at the vertical E-3 test stand. Tests have included small-scale combustion devices such
as catalyst beds, to larger devices such as ablative thrust chambers and a flight-type engine. 39

Testing, development and use of refractory material was evident during the site visit at the E-3
test cell. The original E-3 Cell 2 deflector was fabricated from a metal frame containing precast
Fondu Fyre refractory concrete blocks. The precast blocks were secured to the flame deflector
using steel angles bolted to the 1-1/2 inch thick steel side plates (Figure 21 ).40

Figure 21. E-3 Vertical Test Cell Flame Duct at Stennis Space Center

Tests in this configuration show extensive damage to the steel angles, leading edges and
fasteners. In the hot zone, the one-inch bolts securing the steel wall plates were either melted
away or pulled out due to the thermal expansion (Figure 22). There is evidence that the
refractory material melted from the impingement area and redeposited downstream (Figure 23).

38
E-3 Test Facility. http://sscfreedom.ssc.nasa.gov/esd/ESDTestFacilitiesE3.asp. Last accessed on
November 7, 2008.
39
Jacks, T.E., and Beisler, M. , "Expanding Hydrogen Peroxide Propulsion Test Capability at NASA's Stennis Space
Center E-Complex," 39th AJAA/ ASME/SAE/ ASEE Joint Propulsion Conference and Exhibit, Huntsville, Alabama,
July 20-23, 2003.
40
E-mail correspondence from Nickey Raines, Stennis Space Center, October 7, 2008.

25
NASA/TM-2013-217910

Figure 22. E-3 Vertical Test Cell Flame Duct at Stennis Space Center- After Firing

Figure 23. Close-up view of Damage to E-3 Cell 2 Test Stand

Figure 24 shows a section of early Fondu Fyre that was used at the E-3 Cell 2 Test Stand.
Historical test sections ofFondu Fyre were found throughout the E-3 facilities .

26
 NASAffM-20 13-217910

Figure 24. Fondu Fyre Blocks at the Stennis Space Center E-3 Location

The blocks currently used in the E-3 Cell2 Test Stand is a Fondag DG product. The blocks were
cast in panels at the factory, and were built in a trapezoidal arrangement to overlap with each
successive block. The blocks were cast at 300 °F, which had the result of both lowering the
porosity and increasing the strength of the product. 41

5.1.5 Bldg. 3300 Stennis Space Center

Building 3300 at Stennis Space Center contained remnants of components used for scale model
testing of candidate refractory materials. Examples of these components are shown in Figure 25
and Figure 26.

Figure 25. Test Duct at Stennis Space Center

41
E-mail correspondence from Nickey Raines, Stennis Space Center, October 7, 2008.

27
NASA/TM-20 13-21791 0

Figure 26. Refractory Concrete Apron at Stennis Space Center

These components were used as a part of a program designed to support the acquisition of data
for baseline deflector design and refractory economical requirements. The program had four
objectives:

• Establish ROM bounds on the extent of material loss and damage.

• Develop comparative data on the ability of various refractory materials to withstand the
rocket plume environment.
• Develop engineering and scientific data characterizing surface and plume interaction
phenomena.
• Evaluate, at model scale, the operational capability of the deflector.

Scaling of the test articles was driven by the availability of the Bates motor and propellant
cartridges. The BATES motor (approximately 6000 lb thrust) was fired down the apron in a
manner geometrically similar to that for a full-scale deflector. The plume deflector was designed
in the configuration shown in Figure 27. 42

Several literature sources discussed the design ofthe test assembly, as well testing of refractory
43 44 45 46
concrete materials tested with the test fixture. • • •

42
Douglas, F., Dawson, M.C., and Orlin, P.A., "ASRM Subscale Plume Deflector Testing," AIAA 17th Aerospace
Ground Testing Conference, Nashville, Tennessee, July 6- 8, 1992.
43
Sauve!, J. , "Static Test Defector for Ariane-6 SRM : Technical Design and Economic Choice," proceedings of the
second European Conference on Progress in Space Transportation, May 22- 24, 1989.
44
Orlin, P.A. , Dawson, D.M., and Bourgeois, S., "ASRM Plume Deflector Analysis," Sverdrup Technology, Inc. ,
Report No . 3112-92-016, NASNSSC, March 1992.
45
Douglas, F. ; "Subscale Test Measurement Data Accuracy," Stennis Space Center Report No. 3112-92-013,
NASNSSC, February 1992.
46
"ASRM Subscale Deflector Test Report. Vol. I: Rough Order of Magnitude (ROM) Testing," Sverdrup
Technology, Inc. , Report No . 311292-008 NAS N SSC, December 1991.

28
 NASA!fM-20 13-217910

Figure 27. Stennis Plume Deflector Test Rig

5.2 Cape Canaveral Air Force Station Launch Facilities

The Cape Canaveral Air Force Station (CCAFS) is located on the east coast of Florida in
Brevard County. The facility consists of over 15,000 acres of land, and is bounded by the
Atlantic Ocean to the east and the Banana River to the west. CCAFS is part of the Air Force
Eastern Range that includes administrative headquarters at Patrick Air Force Base, launch sites at
Cape Canaveral, and downrange tracking facilities. The CCAFS area has been used to launch
rockets by the United States government since 1949. 47

5.2.1 Launch Complex 17

Launch Complex 17 (LC 17) was first built in 1956 for the THOR ballistic missile program, but
later was used to launch probes to the Moon and planets, solar observatories, and weather
satellites. LC 17 features two active Expendable Launch Vehicle (ELV) facilities. LC 17 began
supporting launch operations in the late 1950s. The site was upgraded in the early 1960s to
support modem ELVs. Delta II rockets have been launched from the site since the 1960s, though
LC 17B was retrofitted in 1997 to support the Delta III program. The first launch of a Delta Ill
system was on August 23, 2000.

An aerial view of the LC 17 is shown in its entirety in Figure 28.

47
Historic American Engineering Record, Cape Canaveral Air Force Station, Launch Complex 17, U.S. Army
Construction Engineering Research Laboratories, Report No. FL-8-5, December 1997.

29
NASA/TM-2013-217910

Figure 28. Aerial View of LC 17 48

LC 17A is shown to the right of the photograph. It utilizes an open flame trench (in front of the
tower) to route the exhaust away from the Delta II rockets. LC 17B is shown to the left in the
same photograph. In contrast to LC 17 A, LC 17B was redesigned for the Delta III family of
rockets. Changes included the addition of an enclosed flame trench, as well as flame ducts at
each side for the SRBs.

LC 17 consists of two separate launch pads. These pads are designated LC 17 A and LC 17B.
Both launch pads include critical structures, such as the Fixed Umbilical Tower (FUT) and
Mobile Support Tower (MST). 49

Launch vehicles are initially assembled away from the launch complexes, and are only mated to
the FUT after a significant portion of the rocket has been assembled. The FUT includes the
launch pad and the Umbilical Tower (UT). After launch, the refurbishment team is allowed 3 to
5 days to prepare the complex for the next vehicle. Figure 29 shows the major components that
make up LC 17 at CCAFS.

48
Spaceflight Now I Delta Launch Report I Space Launch Complex 17 .
http://www.spaceflightnow.com/delta/d327 /070702slc 17 .html. Last accessed on November 11 , 2008 .
49
Technology Evaluation for Environmental Risk Mitigation Principal Center.
http://www.teerm.nasa.gov/projects/DepaintingPollutionPreventionOpportunityAssessmentCCAFS.html. Last
accessed on November 18, 2008.

30
 NASA!fM-20 13-217910

Figure 29. Major Structures at LC 17 50

Air Force Space Command (AFSPC) and NASA have launch facilities that reside in similar
corrosive environments. Regardless of the corrosivity of the environment, all metals require
periodic maintenance to guard against the insidious effects of corrosion, and thus ensure that
structures meet or exceed design or performance life and ensure mission readiness requirements.
As a conse~uence, LC 17 has been used as a platform for testing and evaluating various
materials. 5

5.2.1.1 LC 17 A

A site visit was conducted at LC 17A on December 11, 2008.

The flame deflector at LC 17 A uses a water deluge system to cool the rocket exhaust and
dampen the acoustic levels. The flame deflector at LC 17A (viewed from the underside) is shown
in Figure 30. The flame deflector was constructed using structural steel !-beams and reinforced
concrete. Seams from the forms that were used for the concrete are visible in Figure 30. In
contrast to other flame ducts, plate steel was not used on the underside of the flame duct
refractory concrete.

50
Depainting and Surface Preparation Pollution Prevention Opportunity Assessment for Cape Canaveral Air Force
Station Space Launch Complex 17, Pads A & B, Final Report.
http://www.teerm.nasa.gov/reports/CCAFS Dep P20A Final Report.pdf. Last accessed on November 19, 2008.
51
Depainting and Surface Preparation Pollution Prevention Opportunity Assessment for Cape Canaveral Air Force
Station Space Launch Complex 17, Pads A & B, Final Report.
http://www.teerm.nasa.gov/reports/CCAFS Dep P20A Final Report.pdf. Last accessed on November 19, 2008.

31
NASNTM-20 13-217910

Figure 30. Underside ofLC 17A Flame Deflector

To protect the supporting concrete from the intense heat of the rocket exhaust, a layer of
refractory concrete (Fondu Fyre) was originally applied for refractory protection. Throughout the
launch program at LC 17, maintenance and repair has been required. To counteract the increased
maintenance cycles, Martyte refractory has been integrated into the launch program.

Martyte was originally developed by Martin Marietta. It is a ceramic filled amine cured epoxy,
and is delivered to the launch site as a three-part system. 52 It is a light colored material with an
off-white appearance. Currently, all Fondu Fyre repairs at LC 17 A are made with Martyte.
Martyte is currently produced by Nitto Denko Automotive in Novi Michigan. Figure 31 shows
the extent to which Martyte is applied to direct (and indirect) blast surfaces at LC 17A and the
proximity to which the rocket nozzles are located in relation to the material.

52
Sprayable Silicone Ablative Coating, GE Product Code CPC-1 050, Post Launch Evaluation on Launch Complex.
4
°Cape Canaveral Air Force Station, Report No . 92-2150, http://corrosion.ksc.nasa.gov/92-2150.htm. Last accessed
on November 19, 2008.

32
 NASA!fM- 20 13- 217910

Fonduefyre

Figure 31. Flame Deflector at LC 17 A

After launch, the flame deflector surface is "dust blasted" to remove soot and SRB residue. Once
the postlaunch cleanup has been performed, the surface is inspected for spalling and ablation of
the refractory materials. These repairs are made with Martyte, and are typically required after
each launch. Figure 32 is an example ofthis requirement, and shows an ablated area of the flame
duct that will use Martyte to cover the exposed Fondu Fyre substructure.

Evidence of prior Martyte patches is clearly visible in Figure 32. Individual Martyte patches,
(such as those shown in Figure 32) are typically required after each launch.

Figure 32. Fondu Fyre Patched Areas Using Martyte

33
NASA/TM-20 13-217910

5.2.1.2 LC 17B

LC 17B was refurbished for the Delta III rocket system, but only two Delta III rockets were ever
launched from the facilities. Part of the refurbishment necessitated the construction of a flame
duct by building two sidewalls to the J-turn deflector. This system uses a water deluge system for
acoustic and thermal protection.

As opposed to LC 17A, LC 17B utilizes a covered flame duct tunnel to convey exhaust 150 feet
downrange and away from the vehicle. Covered ducts were also added to each side of the launch
pad, to safely route the exhaust from the Delta III graphite-epoxy SRB segments. 53

The flame ducts at the side of LC 17B utilize Fondu Fyre for thermal protection (Figure 33).
Fondu Fyre is applied at a depth of3 to 4 inches. Little evidence of wear and abrasion was seen
on the refractory material in this location. This is understandable since the side flame deflectors
are not subjected to the direct impingement of rocket exhaust from the SRBs.

Figure 33. Side Flame Duct at LC 17B

The side flame duct is positioned between the rocket, and an enclosed concrete tunnel that is
used to further route the exhaust from the Delta rocket system (Figure 34). During launch, the
side flame deflector is positioned immediately to the left of the concrete structure that is shown
in Figure 34.

53
Engblom, W.A. , Weaver, M.A., and Nefo, E.D. , ''Numerical Study ofVehicle/Pad Configuration Effects on
Launch Ignition Transients," 39th AIAA Aerospace Sciences Meeting and Exhibit, January 8- 1 I, 2001.

34
 NASA!fM-20 13-217910

Figure 34. Concrete Tunnel Adjacent to LC 17B

An inspection of the side tunnel supporting columns showed visible signs of erosion. Damage to
the concrete supporting columns is shown in Figure 35. The supporting columns were built with
construction grade (Portland cement) concrete. The damage was most likely caused by a
combination of airborne particulates and thermal effects produced by the SRBs during launch.

Figure 35. Damage to Side Flame Tunnel Support Columns

In general, surfaces that are exposed to temperatures below 1500 F can use Portland cement
mixes. Between I 000 and 1500 °F, aggregates in which quartz is the primary phase should be
avoided. Above 1500 °F, ordinary Portland cement can be compromised by the heat. 54

54
Design Handbook for Protection of Launch Complexes !Tom Solid Rocket Propellant, Report
o. Martin-CR-66-11 , Martin Marietta, March 1966.

35
NASAITM-2013-217910

In contrast to the open flame trench at LC 17 A, the main flame trench at LC 17B is an enclosed
duct that was designed to route the exhaust plume away from the rocket. Figure 36 shows the
flame duct construction from the exhaust side of the tunnel. As indicated by the concrete apron
in the center of the duct, LC 17B utilizes a water suppression system.

Figure 36. Enclosed Flame Trench at LC 178

The interior surface of the main flame trench largely consists of unprotected concrete. Exposed
aggregate resulting from erosion to the concrete is shown in Figure 37.

Figure 37. Abrasion to the Interior Surface of Main Flame Trench Walls

The flame deflector at LC 17B is constructed from a Fondu Fyre refractory material over a steel
plate substructure. As shown in Figure 38, the main rocket impingement area in the center of the
flame duct is protected by Martyte over Fondu Fyre refractory concrete.

The sidewalls of the flame duct (Figure 38) show large regions where Fond Fyre is still used for
thermal protection. Once these regions spall and degrade, repairs are made with the alternate
Martyte product Figure 39.

36
 NASA!fM-20 13- 217910

Figure 38. Flame Duct at LC 17B

Figure 39. Martyte Patch on Flame Deflector Side Wall

Repairs to the Fondu Fyre or Martyte are required after virtually every launch. Numerous
patches from these operations are visible in the center of the flame duct in Figure 38.

The use ofMartyte for thermal and ablative protection is not limited to the surface of the flame
deflector. Critical launch components such as the nozzles to the water deluge system are also
protected with the material (Figure 40), as well as bolt heads that are used to secure conduit
enclosures (Figure 41).

37
NASAffM- 2013- 217910

Figure 40. Martyte on Water Deluge System

Figure 41. Martyte-Protected Bolt Heads

The launch deck at LC 17B is positioned directly above the flame deflector. Figure 42 shows the
proximity and distance (approximately 2ft) of rocket nozzles in relation to the launch deck. As
shown in the photograph, Martyte is used extensively on the launch deck of LC 17B. During
launch, the majority of rocket exhaust is routed through ports. These ports are covered by metal
doors as shown in the photograph in Figure 42. Understandably, direct rocket impingement
occurs in areas in close proximity to these ports.

The use of Martyte for thermal protection on the launch deck is extensive. Interviews with LC 17
personnel, and a physical tour of the facility showed that the substructure in front of the line (in
Figure 42) is typical construction grade concrete covered with Martyte refractory protection. The
launch pad substructure in front of the demarcation line is typical structural steel that is protected

38
 NASA!fM- 2013- 217910

by Martyte ranging from 1-112 inches thick near the base of the rocket down to 3/4 inch thick on
the outer edges.

Figure 42. LC 17B Launch Deck

Figure 43 shows a picture of one of the exhaust ports that had the protective metal cover
removed for access. As shown in the figure, all direct impingement areas (perpendicular to the
rocket blast) are covered with the thermal ablative. Surface areas that run parallel to the exhaust
plume largely consist of structural steel that is coated for corrosion protection.

Figure 43. LC 17B Exhaust Port on Launch Deck

39
NASNTM-20 13-2 17910

Additional launch deck components are protected with a red thermal ablative coating
(Figure 44). The pliability of the material would indicate that ablative is silicone-based.
However, this supposition cannot be confirmed since the product is a Boeing proprietary
formulation.

Figure 44. Ablative Coating on Tubing in Center of LC 178 Launch Deck

5.2.2 Launch Complex 34

Launch Complex 34 (LC 34) was built in the late 1950s, and was constructed to launch the
Saturn 1 and Saturn 1B family of rockets. Saturn l B which is the larger of the two rockets, was
223 ft tall (with the Apollo capsule atop), and developed 1.6 million pounds of thrust at liftoff. 55

From 1961 to 1968, four Saturn rockets were launched from LC 34. Unfortunately, the site is
best known for the fire that killed astronauts Gus Grissom, Ed White, and Roger Chafee in a test
for the Apollo 1 mission. 56

An archived photograph shows the launch position of the flame deflector beneath the LC 34 pad
during construction (Figure 45).

55
John F. Kennedy Space Center- KSC Fact Sheets and Information Summaries. http://www-
£ao.ksc.nasa.gov/nasafact/count l.htm. Last accessed on December 17, 2008.
6
Pad 34. http://www. floridatoday .com/apps/pbcs.d11/article? AID=/99999999 EWS09/603120 1711007 . Last
accessed on January 5, 2009.

40
 NASA!fM-2013-217910

57
Figure 45. LC 34 Flame Deflector and Launch Pad

The original flame deflectors remain at the historical LC 34 launch site. These items were
inspected on December 11, 2008.

Prior to the inspection, several NASA personnel had indicated that the flame deflectors were all
metal (water-deluge-cooled) units. An inspection of the facilities and flame ducts (Figure 46)
showed that a thermal ablative was indeed integrated into the design as a key component. A
visual inspection of the flame deflectors indicated that the depth of the refractory material varied
quite extensively, though it was thickest in the areas where the floor and walls of the flame
deflector meet.

Figure 46. Flame Deflector at LC 34 on December 11, 2008

57
Moonport, CH2-4; http://www.hg.nasa.gov/office/pao!History/SP-4204/ch2-4.html. Last accessed on
December 17, 2008.

41
NASA/TM-2013-217910

Figure 47 shows a magnified section of the refractory material in the center of the flame
deflector floor.

Figure 47. Refractory Material at LC 34

As of the writing of this report, the authors were unable to determine the product identity, nor the
vendor for the refractory material. This is understandable considering the significant age of the
structure and the number of years that the item has remained as a historical remnant of the
Apollo era.

5.2.3 Launch Complex 36

The military constructed Launch Complex 36 (LC 36) for the Atlas rocket program. A second
pad was added in the mid 1960s.

NASA operated the launch complex for most of its service life and launched scientific missions
that included:

• Surveyor spacecraft that landed on the moon in advance of the manned Apollo missions.

• The Mariner robotic probes for Mars and Venus.

• Several Pioneer long-distance probes.

• Numerous commercial and military satellites.

LC 36 is no longer used for launch and was decommissioned from use in 2005. 58 Structural steel
from the launch pad was removed from the site and used as an artificial reef in the Atlantic
Ocean. Based upon a Lockheed-Martin article pertaining to this operation, it was determined that

58
Pads 36A & 36B. http://www.floridatoday.com/apps/pbcs.dll/article? AID=/99999999/NEWS09/603120 1811007 .
Last accessed on January 6, 2009.

42
 NASA!fM-20 13-217910

Martyte was a key refractory material used on the flame deflector along with Fondu Fyre
refractory concrete.

Information regarding the refractory concrete used at the site was unavailable but a search of the
literature revealed that Martyte was used as a component of the flame deflectors. 59

5.2.4 Launch Complex 37

The construction ofLaunch Complex 37 (LC 37) began in 1959 to support the Saturn m rocket
program. LC 37B was used for unmanned Saturn I and m flights through the mid 1960s.

LC 3 7 was completely refurbished in the late 1990s. Completion of the project occurred in 2000
with funding financing from the Florida Space Authority. Currently, the facility is used by
Boeing to launch the Delta 4 series of rockets.

The first heavy version of the Delta 4 flew from Pad 37 in December 2004.60 A prelaunch
photograph of the vehicle is shown in Figure 48.

Figure 48. Delta IV Heavy at Launch Complex 37 61

59
Lockheed Martin New Horizons. http://www.lockheedmartin.com/data/assets/10006.pdf. Last accessed on
January 5, 2008.
60
Pad 37. http://www. floridatoday .com/apps/pbcs.diVarticle? AID=/99999999/NEWS09/60312023/ l 007 . Last
accessed on January 5, 2008.
61
Delta 4 Heavy. htto://www.astronautix.com/graphics/dldelta4h.jpg. Last accessed on January I, 2009.

43
NASA/TM-2013-217910

A search of the literature indicated that Fondag DG is the principal refractory concrete used at
LC 37. 62 Based upon the referenced source, Atlantic Firebrick of Jacksonville, Florida, was
contacted for further information.

Atlantic Firebrick confirmed that Fondag DG was the principal refractory material in use on the
flame deflector at LC 37. Kruzite GR Plus, which is a gunnable refractory concrete, was also
used at LC 37. A desirable quality ofKruzite GR Plus centers upon its ability to adhere to
overhead structures better than Fondag DG. Therefore, less rebound is experienced with this
product. 63

Further information regarding refractory materials in the flame trench at LC 37 was unavailable
at the time this report was finished. Because of the proprietary and secretive nature of the Delta
IV launches, flame trench materials and designs were closely guarded by LC 37 launch
personnel.

5.2.5 Launch Complex 40

Launch Complex 40 (LC 40) was used by the United States Air Force to launch Titan III and
Titan IV rocket systems until April2005. The Titan III system was principally used to launch
commercial satellites. 64

LC 40 utilizes a water deluge system for thermal cooling and sound suppression. Discussion with
Kemeos Aluminate Technolo~ies personnel indicated that the principal refractory concrete at LC
40 is the Fondag DG product. 5 Additional information on refractory materials at the launch site
was obtained from NASA Test Report No. 92-2150. 66 This test report illustrated the use and
performance ofthe General Electric (CPC-1050) Silicone ablative coating on structural steel.
The performance this product was rated as excellent after it was exposed to Titan 34D launch
conditions.

The same report noted that Martyte was a product in use at the facility, and made specific
mention of the standard practice of protecting water deluge nozzles with the material. The same
report commented on possible incompatibility issues between the silicone ablative and epoxy
Martyte refractory. After the launch of a Titan 34D rocket, Martyte refractory sections (that were
applied over the silicone ablative) delaminated from the underlying surface.

On April25, 2007, LC 40 was leased to SpaceX to launch their Falcon 9 rocket system. NASA
selected the SpaceX Falcon 9 launch vehicle and Dragon spacecraft for the International Space

62
Fitzgerald, M.W., Talley, J. , and Alt, C.W., "Calcium Aluminate Technology and Its Application in Refractory
Concrete," Shotcrete, Summer 2002.
63
Telephone interview with Doug Goddard, Atlantic Firebrick, January 6, 2008.
64
Pads 40 & 41 . http://www.tloridatoday.com/apos/pbcs.dlUarticle? AID=/99999999/NEWS09/6031202111 007 . Last
accessed on January 9, 2009.
65
Telephone interview with Greg Wallace, Kemeos Aluminates, January 6, 2009.
66
"Sprayable Silicone Ablative Coating, GE Product Code CPC-1 050, Post Launch Evaluation on Launch
Complex," NASA Report No. 92-2150, November 23 , 1992.

44
 NASA!TM-2013-217910

Station Cargo Resupply Services (CRS) contract award. Under the contract, SpaceX will be
responsible for 12 flights between 2010 and 2015. 67

According to the Falcon 9 data sheet, the total thrust from the SpaceX Merlin engines is
estimated at 1.125 million foot pounds.68 Estimated thrust for the Falcon 9 Heavy is estimated to
be 3.375 million foot pounds. 69

According to Kemeos Aluminate Technologies personnel, SpaceX continues to use Fondag DG

as the principal refractory material in the flame trench at LC 40.70

5.2.6 Launch Complex 41

Launch Complex 41 (LC 41) was initially built to support the Titan launch program. The first
Titan 3C was launched from this facility in December 1965. The last Titan flight to occur was in
Aprill999.

To accommodate the new Evolved Expendable Launch Vehicle (EELV) program, LC 41 was
redesigned and rebuilt for the new Atlas V series of rockets. Atlas V is an expendable launch
vehicle that is built through a joint alliance between Lockheed-Martin and Boeing under the
name United Launch Alliance. 7 1

Preparation for the new launch system necessitated the removal of the Mobile Service Structure
and construction of a Vehicle Integration Facility. The Vehicle Integration Facility, was finished
in 2000, and a new Control Center was completed in 2001.

The Atlas system has launched numerous commercial satellites from LC 41. Other payloads have
included NASA's Mars Reconnaissance Orbiter and the Pluto New Horizons probe. 72

LC 41 Refractory materials were investigated for this report. The refractory materials at LC 41
must be able to withstand the deleterious effects produced by the kerosene\LOX fueled rocket
motor and up to five SRBs. 73 To counteract the heat and acoustics of the rocket system, a water
deluge is activated three seconds into the launch.

67
Space Exploration Technologies Corporation - SpaceX. http://www.spacex.com/. Last accessed on
January 6, 2009.
68
Falcon 9 Launch Vehicle Data Sheet. htto://www.spacex.com/Falcon9DataSheet.pdf. Last accessed on
January 12, 2009.
69
Space Exploration Technologies Corporation - Falcon 9 Heavy. http://www.spacex.com/falcon9 heavv .php. Last
accessed on January 12, 2009.
70
Telephone interview with Greg Wallace; Kemeos Aluminates; January 6, 2009.
71
Pads 40 & 41. http://www.floridatoday.com/apps/pbcs.dll/article?AID=/99999999/NEWS09/6031202111 007. Last
accessed on January 9, 2009.
72
Pads 40 & 41 . http://www.floridatoday.com/apps/pbcs.dll/article? AID=/99999999/NEWS09/60312021 / 1007. Last
accessed on January 9, 2009.
73
Atlas V data sheet. http://www.ulalaunch.com/docs/product sheet/ AtlasProductSheetFINAL.pdf. Last accessed
on January 9, 2009.

45
NASAJTM-2013- 217910

The Atlas V flame bucket was rebuilt specifically for the Atlas V system. A review of the
facilities indicated that the flame deflector utilizes Fondu Fyre refractory concrete, over a
reinforced concrete substructure. To further protect the flame deflector, a Havaflex phenolic
ablative coating is applied to a depth of approximately 1 inch.

Havaflex is a trowelable and sprayable phenolic ablative coating that was originally developed
for the U.S. Navy to protect decks, bulkheads, and shipboard launchings systems. The product
was designed for high tem~erature (up to 5000 °F.) and high gas velocity (up to MACH 3.0)
missile launch operations. 4

Additional refractory protection is afforded with the use of the Martyte epoxy ablative on
instrumentation in the flame trench at LC 41. In contrast, a silicone ablative coating is used to
protect connections from excessive heat, erosion and ablation ..

Because of the proprietary and secretive nature of the launch activities at LC 41, photographs of
the launch pad and flame duct system were not allowed, and therefore could not be included in
this report.

5.3 Vandenberg Air Force Base: Launch Complex 6

With the advent of the missile age in the 1950s, Vandenberg AFB (Camp Cooke at the time) was
chosen as America's first combat ready missile base. This decision was based upon size,
remoteness from heavily populated areas, desirable climate features and coastal location. The
proximity to the ocean is also beneficial, since it provides a margin of safety by avoiding flights
over populated areas.

On December 16, 1958, Vandenberg successfully launched its first missile, a Thor intermediate
range ballistic missile (IRBM). Over the years, Vandenberg has been used as a location to launch
unmanned satellites. As of November 2005, a total of 1858 orbital and ballistic missiles have
been launched from Vanden berg AFB facilities.75

Launch Complex 6 (LC 6) was originally designed for the Titan Ill program, and eventually was
transformed through a 4-billion-dollar modification for the Space Shuttle. For reasons beyond
the sco~e of this report, Space Shuttle operations were centralized to the Kennedy Space
Center. 6

In the late 1990s, Boeing modified LC 6 for the Delta IV series of rockets. To date, the modified
facility has been used to launch the Delta IV Medium, and Delta IV Medium + series of
rockets. 77

74
Havaflex T.A.-117 A Trowelable Ablative Material. http://new.ametek.com/content-
manager/files/HAV//Havaflexl.pdf. Last accessed on January 9, 2008.
75
Vandenberg Air Force Base- Fact Sheet; Vandenberg Air Force Base- Fact Sheet.
http://www.vandenberg.af.mil/library/factsheetslfactsheet.asp?id=4606 . Last accessed on January 9, 2009.
76
Space Vehicles: History Office. http://www.vandenberg.af.mil/librarv/factsheetslfactsheet.asp?id=4606. Last
accessed on January 9, 2008.
77
Boeing: Boeing Completes First Delta IV West Coast Launch.
http://www.boeing.com/ids/network space/news/2006/g2/060627b nr.html. Last accessed on January 9, 2009.

46
 NASA!TM-20 13-217910

Figure 49 shows the assembly building (in the foreground) for the Delta IV rockets at LC 6. The
water deluge system that is used for launch operations is shown in the background of the same
figure. The deluge water is recovered after each launch, recycled, and discharged in accordance
with applicable industrial wastewater permits and regulations.78

Figure 49. LC 6 at Vandenberg Air Force Base 79

Kemeos Aluminate Technologies was contacted to ascertain the extent to which their product
was used at Vandenberg Air Force Base. Kemeos personnel indicated that Fondag DG was used
°
as the primary refractory concrete at LC 6.8 Further discussion indicated that other launch
facilities at Vandenberg only utilized construction grade (Portland cement) concrete. Because of
the proprietary and secretive nature of launches at Vandenberg, the authors of this report were
unable to verify this statement.

5.4 Palm Beach County Fire Training Facility

The Palm Beach County Fire Rescue Administration and Training complex was designed to
provide training simulations designed to meet the needs of the fire service.

The 40-acre complex is located on Pike Road, near the entrance to the Florida Turnpike, and
houses administrative offices, training classrooms, practical training areas and an apparatus and
support building. The concrete bum building (under construction) is designed to simulate a
two-story 4200 ft 2 residential structure. 81 An exterior view of the facility is shown in Figure 50.

78
Final Supplemental Environmental Impact Statement (FSEIS) for the Evolved Expendable launch Vehicle
(EEL V). http://www.faa . gov/about/office org/headguarters offices/astllicenses permits/media/SEISROD2000-
2000 .pdf. Last accessed on January 9, 2009.
79
Boeing: Multimedia - Image Gallery - Delta IV Launch Site - Space Launch Complex 6.
http://www.boeing.com/companyoffices/gallery/images/space/delta iv/d4 slc6 08.html. Last accessed on
January 9, 2009.
80
Telephone interview with Greg Wallace, Kemeos Aluminates, January 6, 2009.
81
Palm Beach County Fire Rescue - Herman W. Brice Training Complex Construction Information.
http://www.pbcfr.org/training construction. asp . Last accessed on November 4, 2008.

47
NASA/TM-20 13-217910

The late construction timeframe provided a unique opportunity to inspect the refractory system
and its installation.

Figure 50. Palm Beach County Fire Rescue Training Facility

The refractory system used in the Palm Beach County Fire Rescue Training Facility was
provided and installed by High Temperature Linings in Fairfax, Virginia. 82 The trade name of the
company' s refractory product is System 203. Per the manufacturer, System 203 is able to
withstand repeated high temperatures and extreme thermal shock created during fire training
exercises.

Each System 203 Firetile is individually anchored to the structure with a stainless steel anchoring
system (Figure 51). Coupled with the interlockin~ feature of the tiles (Figure 52), the lining is
allowed to "float" with temperature fluctuations. 3

82
High Temperature Linings, 606 Chesapeake Drive, Suite C, PO Box 1240, Whitestone, Virginia 22578,
(800) 411-6313 .
83
High Temperature Linings. http://www.firetrain.com/system203/system203 .html. Last accessed on
January 9, 2009 .

48
 NASA!fM-2013-217910

Figure 51. System 203 Tiles at the Palm Beach County Fire Training Center

Per the manufacturer, the system is designed to last for 10 to 20 years (for Fire Training
Buildings) with only minimal maintenance. The system is: 84

• Designed for maximum temperatures between 1600 and 2200 °F.

• Resistant to thermal shock. The lining is designed to "float" on top of a calcium silicate
insulation board.

• Suitable for all types of buildings. The lining anchors to concrete masonry units.
Alternatively, it may be installed to a framework of channels anchored to structural steel
if proper ventilation and waterproofing measures are taken.

• Designed to keep water and steam out (for interior fire training buildings). The ship-
lapped design protects the insulation and structure from water, steam, and heat damage.

The interlocking design of the System 203 tiles is shown in Figure 52.

84
High Temperature Linings. http://www.firetrain .com/system203/system203 .html. Last accessed on
January 9, 2009.

49
NASA!fM-20 13-217910

Figure 52. Interlocking System 203 Tiles

The system 203 tiles are produced from a proprietary formulation that contains stainless steel
fibers for strength. The insulating (and structural concrete protecting) properties of the system
result from the use of a calcium silicate backboard underneath the temperature resistant tiles. 85

The System 203 product is marketed as a rugged product that is capable of withstanding the
abuse of high-pressure streams of water. 86 Unfortunately, the use of System 203 in this manner
is not comparable to the launch pad environments at KSC. These environmental conditions
include extreme erosion, ablation, and greatly fluctuating temperatures. Furthermore, the
complexity of the system, while useful for the interior of a building, may present problems for
postlaunch repairs and maintenance.

6 CONCLUSIONS •
Refractory concrete is used to protect National Aeronautics and Space Administration (NASA)
launch structures from elevated temperatures, ablation, and erosion. The only refractory material
qualified for use at Launch Complex 39A (LC 39A) and Launch Complex 39B (LC 39B) is
Fondu Fyre W A-1 G which is supplied by the Pryor Giggey Co. The material was developed
solely for NASA in the 1960s.

Refractory concrete at LC 39A and LC 39B have become susceptible to failure, resulting in large
sections of the materials breaking away from the base structure. During launch, these sections
become high speed projectiles that jeopardize the safety ofKSC personnel, and have the
potential to damage ground support equipment and the Space Shuttles.

85
System 203. http://www.firetrain.com/PDFs/system%20203.pdf. Last accessed on January 9, 2009.
86
High Temperature Linings. http://www.firetrain.com/system203/systern203 .html. Last accessed on
January 9, 2009.

50
 NASA!fM-20 13-217910

A review of the current specification and requirements for refractory materials indicates that the
test methods and qualification criteria are not well defined. Consequently, the only refractory
product qualified for use at KSC may not have the material properties necessary to survive
extended exposure to Florida coastal environments and the severe launch conditions exhibited by
the Space Shuttle. As a result, better performing refractory materials may be available for use at
KSC.

A literature search was conducted to ascertain the different categories of refractory materials that
are available for the protection at KSC ' s launch pads. The classes of materials were categorized
as follows:

• Firebrick
• Refractory Concrete
• Silicone and Epoxy Ablatives

Based upon this information, a literature survey was conducted to locate industries that had
refractory requirements that were similar to NASA ' s. Based upon this survey, site visits, and
interviews with pertinent industry personnel and refractory vendors were conducted. The
following list summarizes the site visits, rockets, test site load capacities, and the materials used
to protect the flame deflectors.

• Stennis Space Center

o A-2 Test Facility
• Metal flame deflector
• 1.1 million foot pound capacity
• Liquid propellants
o B 1 and B2 Test Facilities
• Metal flame deflector
• 11 million foot pound capacity (each structure)
• Liquid propellants
o E-2 Test Facility
• Unknown refractory concrete flame deflector
• 100,000 foot pound capacity
• Liquid and RP-1 propellants
o E-3 Test Facility
• Precast Fondu Fyre flame deflector (original)
• Precast Fondag DG flame deflector (current)
• 25,000 foot pound capacity
• Liquid, hydrogen peroxide and hydrocarbon fuels
o Bldg 3300
• Remnants of multiple refractory tests (from Edwards AFB/JPL
testing)
• 6000 foot pound thrust for testing
• Bates solid rocket motor

51
NASA/TM- 2013-217910

• Cape Canaveral Air Force Station

o Launch Complex 17
• Fondu Fyre WA-lG and Martyte refractory material along with
a Boeing proprietary ablative
• Delta II and Delta III
• Liquid and solid fuels
o Launch Complex 34
• Unknown refractory concrete flame deflector
• Saturn 1 and Saturn 1B Rocket Systems
• Liquid fuels
o Launch Complex 36
• Fondu Fyre and Martyte refractory materials
• Atlas I, Atlas II and Atlas Ill
• Liquid and solid fuels
o Launch Complex 37
• F ondag refractory concrete
• Delta IV
• Liquid and solid fuels
o Launch Complex 40
• Fondag refractory concrete, Martyte and GE silicone ablative
• Titan Ill, Titan IV, Falcon 1 and Falcon 9
• Liquid and solid fuels
o Launch Complex 41
• Fondu Fyre W A-1 G refractory concrete, Havaflex phenolic,
and various silicone ablatives
• Atlas V
• Liquid and solid fuels
• Vandenberg Air Force Base
o Launch Complex 6
• F ondag refractory concrete
• Delta IV
• Liquid and solid fuels
• Palm Beach County Fire Department
o Fire Training Facility
• Proprietary precast refractory cement and calcium silicate
insulating backboard system
• Hydrocarbon fuels

As a result of the site visits and interviews, a series of products for launch applications were
found.

52
 NASA!fM-20 13-217910

Firebrick, while historically used near flame deflectors at NASA launch sites, was not found at
any of the locales investigated in this report. Product and labor costs associated with the
installation of the materials were cited as the driving factors for its lack of use.

Refractory concrete was used at numerous launch locations. Currently used products include
Fondu Fyre W A-1 G which is produced by the Prior Giggey Co., and Fondag DG, which is
supplied by Kerneos Aluminate Technologies. Both versions are gunnable, and as a result,
benefit from reduced labor costs associated with the application of the product. Kruzite GR Plus
is another refractory concrete that is noteworthy. Kruzite GR Plus is currently being used and
was recommended for use in overhead flame duct locations due to its better adhesion (less
rebound) properties.

The direct impingement areas (of the flame deflectors) were often found to be protected by a
ceramic filled epoxy called Martyte. Martyte was often used to replace and protect refractory
concrete that had deteriorated. Furthermore, structural steel (in direct impingement areas) was
often protected by the product.

Havaflex is a phenolic ablative that is produced by Ametek Chemical Products. It can be either
troweled or sprayed as required, and is used in areas that are subject to direct rocket exhaust.

Various silicone ablative materials were used outside direct blast areas. These coatings included
the General Electric GE 3404 ablative, as well other proprietary formulations from other
manufacturers and aerospace companies. These products are often used to protect structural steel,
launch pad tubing, and connectors for launch pad instrumentation.

None of the products in this trade study can be considered a panacea for LC 39A and LC 39B.
Fondag DG, while inexpensive, was often top coated with Martyte for repair or additional
thermal protection.

Martyte is costly and difficult to apply. Furthermore, incompatibilities between Martyte and the
silicone ablatives may be of concern.

Havaflex is a phenolic ablative material that is easy to apply; unfortunately, it is costly and
requires frequent replacement.

The silicone ablatives are inexpensive, easy to apply, and perform well outside of direct rocket
impingement areas. When used in locations subject to direct rocket exhaust, the performance of
the coating is exceeded by refractory concrete and the epoxy alternatives.

As discussed in this report, the site inspections and interviews with launch complex personnel
revealed that the number of refractory products routinely used for launch applications is
extremely limited. In a separate report (WBS 5.2.2.1.6 COTS vs. Refractory Materials
Requirements for Flame Deflector Trade Study) that is in preparation for NASA ' s Technology
Development Program, over 800 products were identified and their material properties were
documented. The cold modulus of rupture, hot modulus of rupture, thermal conductivity, cold
crushing strength, application method and (manufacturers reported) recommended service
temperature were used to assess the product for flame deflector use. Once ranked by these

53
NASA/TM-20 13-217910

reported specifications, over 114 products were determined to be viable candidates to be

considered for physical testing and evaluation under NASA's stringent requirements. 87

This report summarizes the ablative materials that were found at industries with refractory
requirements that are similar to NASA's. The refractory products, individually or in
combination, may be considered for use at LC 39A and LC 39B provided the appropriate testing
requirements and specifications are met. Unfortunately, due to the extreme conditions
experienced at LC 39 and unique nature of the launching rockets, none of the products promise
to be the drop in replacement that will solve the delamination and spalling of refractory materials
that occurs at NASA's launch sites. Further testing of promising candidates needs to be
addressed.

87
Calle, L.M. , Hintze, P.E., Parlier, C., Curran, J.P. , Kolody, M.R. , Perusich, S.A., Whitten, M.C., Trejo, D.,
Zidek, J. , and Coffman, B., "WBS 5.2.2.1.6 COTS vs. Refractory Materials Requirements for Flame Deflector
Trade Study," National Aeronautics and Space Administration, in preparation.

54
 NASAffM-20 13-217910

APPENDIX A. PRODUCT DATA SHEETS

~ TECHNICAL DATA
The
CO.
Re fra~:t" ry Speci1ltist.t"
A divisiou fP-G hlcb.ttles.lnc
..V EMf'J.OYE£ OWNHD CO. UMJI.ry

roNDU FYR.r! W' -lG i an eronon rnill:alt s111lfttig ronciete de~ tor expotOre l9 i'odet engine.
exhiUil rot law:b otUJf iLafta "JlPliClliililll. - .

Maim m.Reoo.matled UaeT•per.tft . ...... .. ... ... . Sl&linedt~p. 220()0f

Mama .Requlredt , . • . • . . . . . . . • . . . . . . . . . • . . . . . . . . . . • • . . . • . . • . . . . 120. 125 l'Cr
~.a,C~dM(y {~tu-inlb•ftl,"Ej; .... , .. . •. . , .•. :S.O~ JO~"F. S:2@ ISOOO'F

e~ Cr~l ~treqtll,(pti rj}:1 d-,vs) . .. . , ..•. . •. . .••• . .. . •.•• ... : 4J~O • 6;000

~ty {%,) .... .. - ' :••. . . ·--.. ....... . ' . ....... . '. . . . . . . .. . .... ... ... -... .. 16
Coertdut neralll ExpaMtoa·(Xt0-4JialJaPJ) . . ... . ..... . . .. ....... . . .•. , , , 4.S

c-..c;JIIAM)'11s
~~ ...... .·..... ... ...... .. ...... .... .... ....... ........ ........ ... u.s~
~ • t o • I t o I .. t • t o "' I I t f"' t j t I I . o t t. I I I t I • t • t I o I I • t. t I t o o .. o t • I I o I t o • • I t 34-~

F~ .... . .. . , . .. .. , . ..... . . .. . . . ..... . . ... .. . , . .. , .•• .. .... . • . . ...•.. ll.S~

TiO, ..•. .... • . •. .... •.•• . • ..• ..•.• .... •..• .... • .• . .... ...• . .. . •.••.. . O%

~ ..: . .... . :S~mlbUtt.~

O.ULutRe.tted: . •... .. .... 9189

Ql.ci!.DI~ WA • Mllimn,AL
l• · 146•11i$
All ' 'I~ : rilH I ~'l tra. ;l>i1111 r-«<1 ' .' lt1 • .-w

55
NASA/TM-20 13-21791 0

Product data sheet

Fond

Q General Characteristics I J Speclflcatlons

FONDAG' OG procklced and cltlributed in Noith
Composed .m.ly of Clllc:ium llumiMtes, FON~~
OG is a Pf'e11ac:lolged rudy to use high shnglh dry
Amenc:. Klleres to lhe illlowing spec:ilk:lllioos:
glrite.
FONDAG' OG is a ~ that can be used in
sell'lft cUy ln~us1rial COI'ICnlte applicalions thlt may Min(%) Max(%)
require ....t.ctDry priJnnance. jJ.f iUSmm) 0 0
FONDAG• OG is recommMded ior concna • 8 12.38rnml 0 12
appllc3lions requiring rapid ha'derli~ ptq)erties, fl16 (t 18111111 23 46
113011100 1Jml .41) '65
reSstance to atnsion and mecharical shock.
resisa.nce to dl«nlcal .ttaclc and exposute to ti-50 {300 1Jml 50 72
.....-.ctorytemp...tl.n$ < 2000" F. Al100 1tSOuml 57 76
AI200 051AI 81 79
FONDAG• OG does not release Clllr::ium hyctoxide as p., 20 .41)
a hydration product. This imparis good
refi'adoriness, chemiCal n1 sistal~ee .nc1 llliminates the
mllior cause of ellonscence.

data is..,.
FONDAG• OG is a Wit'/ daJk WilY cd«. ColorinMIUy
C!n reguest. o Plliwba•...., F-' s.t: 2- 5 hours

FOND~ OG does not conllin any addiMK.. Fof"delaiko6 t..a ~. pleese oeont.d a l<8meGs Ted'llical
.,. QuolliyM~~r~~ger.
FOND~ OG does not CCI'IIIin crystaline tilica.

IJ Additional Physical properties

Kemeostnc.
1316Pno l-~ VA 233:M
Pllone 17511~3'200 ·FAX. (75112$4-.3300

hlet~

56
 NASA!fM-20 13-217910

Product data sheet

D Packaging & Shelf Ufe c:cncretes, l is recommended tMt FONDA~ OG not

be p!M:ed cWtoors or in clrect COI'Uct wlh lie
gRU'Id. Vthen carr.ctly stcnd in dry concltion lie
FON~ OG is w.illlble piletzed in 651b bags. prqJ«ties d FONOA.c;e OG Villi remain '411111\
specilcalian limit b . least e monlhs. In most
FONDAG• OG pacbG~ Is detlgned to prdect I cases b properties will be nhined fOr tNWa ye..
i'om humidly. H~. a wlh al PAIPacbaed

KERNEOS LMTEDWARRANTY
Kemeos w.nants tqt this product. Jt the tined shipmd, conforms to lhe SpeciiCIIIions set forth in section 2 d
this Product Data Sbeel AI olh• il'lfonnation pn:Mded in this Product Dllla Sleet Is for guldilnc:e only. AU
OlliER WARRANTIES. ~UDING WTHOUT LNJTATION lHE WARRANTES OF MEROiANTABIUTY AND
FITNESS FOR A PARTICULAR PURPOSE, ARE EXCWDEO. Kemeos' sde ollligalion and lie sole~
excllsiYe rwnedy under ltlis limited ~ shall be the repiKeiMilt d •ny nonconfcnnlng product, or, Jt
Kemeos' cptiof\. the rel.rd ·d the purehne price.. No wwrwty is given fer any techniclll 8IMce or
recommaldaions proWled by Kemeos. Buyer WIIMis .- c:laims under Ills lmited w.ranty \.nless I has SliYfln
wrilt... notice dnonconformity within 30 daY$ ar deliwfy.

Kemeoslnc.
t315Ptlo~L-~. VA :23324
Ria. 11571'284-3200-FAlt (7571284-3300
.._J~

1:50111111

57
NASA/TM-2013-217910

Product Data
10/08: 5885

KRUZITE® GR PLUS

Physical Properties: <Typical) English Units Sl Units

Description: 70% Alumina Gunning Castable

Maximum Temperature 3200"F 1760"C

3 3
lblft g/cm
Material Required 145 2.32

Bulk Density
After220.F(105• c) 149 2.39
After1500" F (815.C) 145 2.32
After2500"F(1371 "C) 142 2.27
After2910"F(1600"C) 142 2.27

Water Required for Premixing See Mixing & Using Instructions

Permanent Linear Change, %

After1500. F(815"C) -0.2
After2500"F(1371 "C) 0.0
After2910"F(1600"C) +0.9
2
Modulus of Rupture lbfm MPa
After 220"F (105. C) 1500 10.3
After1500"F(815"C) 1000 6.9
After 2soo•F (1371 •C) 1700 11.7
After2910"F(16oo•c) 2000 13.8

Hot Modulus of Rupture

At 25oo•F (1371"C) 750 5. 2

Cold Crushing Strength

After 220"F (105"C) 4800 33.1
After1500" F(815"C) 5800 40.0
After 2500"F (1371"C) 7100 49.0
After2910. F(1600. C) 4600 31 .7

Thermal Conductivity
At a Mean Temperature of Btu-inlhr·tr·"F Wtm··c
400"F (205"C) 9.8 1.41
800"F (425"C) 9.1 1.31
1200"F (650"C) 8.6 1.24
1600"F (870"C) 8.3 1.20
2000"F (1095"C) 8.2 1.18
2400"F (1315"C) 8.2 1.18

(Continued)

58
 NASA!fM-2013-217910

Product Data

KRUZITEe GR PLUS (Continued)

Chemical Analysis: (Approximate)

(Calcined Basis)

Silica (Si02) 26.2%

Alumina (A~03) 67.6
Titania (Ti02) 2.1
Iron Oxide (Fe~3) 1.1
Lime (CaO) 2_8
Alkalies (Na20+K20) 0.1

Description: KRUZITE GR PLUS is a 70% alumina, dense, 3200"F maximum service temperature
gunning castable. It exhibits excellent strengths and high densities. Typical applications
are: iron torpedo ladle and hot metal mixer gunned maintenance linings, general steel
mill maintenance material, air heater linings, boiler repairs, soaking pit bottoms, high
temperature ductwork, and high temperature stack linings.

The test data shown are based on average results on production samples and are subject to normal
variation on individual tests. The test data cannot be taken as minimum or maximum values for
specification purposes. ASTM test procedures used when applicable.

10/3108 Dev.

59
NASA/TM-2013-217910

HAVAFLEX T.A.·117
A TROWB.ABLE ABLATIVE I'M1ERIAL
Produd o.atptilln
H.,lflex T.A ~ 1171s a two-compooert mocllled phenolic ablatiVe coating an~ aclle!We. This material was originally
developed for use D! the. U.S. Navy to provide a fleXIble trii'Miable coating material to protect decks, bul<heeds, and
shipboard launchings systems from the extreme~)~ high temperatures (up to 5000'F .) and high gas vetoc lies (up to MACH
3.0) present during nissle launch operatioos.

TIICIINCII Dale
Prapertln
H.,lflex T.A.-117 Is ftaclble, an excelert thermallnstJator, ¥1411 not sop port combUstloo, and Is rest start to many
chaTllcal envlroomerts, lncl.lding acid and sal solrtlons. The material has a pot lfe. of 30 to 40 nintJes at room
temperature and cureswthin·24 to 36 hours. The shir tre inpprCICimatett ooe year·v.tlen stored at 40"F or bf!low.
Hwaftex TA-117 ¥1411 edhare to aln1ost all types of surfaces (free f! moisture, dirt, or grease) wthout the need ct a primer.
H.,lflex T.A.-117 can be machined, saY~ed, planed, tlrllleil, ground or sanded, spun rnoldeil aniS can be'appJie~ vertically
In %inch layers to de·stred thickness wthout sagging.

~Pr.......
Tensle Stren"h (psl) ............ 625 Tensle Lap Shear (p9) ..... 625
(ASTM D 638) (ASTM D 1001,1

Tensle Eloogatkm, 'lr........... ,12.8 Water AbsorPkln, 'lr.

(ASTIII 0 638) (96 trs. at65-75"F) .. ...... . 0.67

Density (lbsllb) ...................81 .2 Flame Spread lndex .. ....... 143

(ASTIII E,62)
Specific Oraotlty ........ .... ...... 1.30
CCJferage (11hhic~ .... .. 6.2ftz per 1<1
Thermal Conductivly ... ........3.56
(Btulfl2J" F.lhrfln of path) Coelfkiert of Thermal Expansi:m
(irltnrCx1 0-4) perpendicular 290
Shore Hardn'ess..................... 90 (irli'II"Cx11k) paralel7.00
Type A
Specific Heat ......................o. 206
(ASTM E 1269-94)
(Btullbi"F)

Padc8glng '
H.,..... T.A.-11115 wallable In on•galon kls, and Is packaged In plastlc .cortalners ¥ol1h Part A and Part Bin separate
cortalners. The two COfl1lOnents can be easily rmced tooelher lrf using a %Inch electric ctlll ¥ll1h a stainless steel JlftY
nilling blade.
Produd Bulllllln H_,..... T.A.-117 A T,_..,e Abllltllte _...Raw.. 8.12W8
Ttisintormlllan 181 blh herein Is ln'tlstled tee ofctoerge end Is~ ontecmlcal detaWif;;ti,IMETEK belle'.eslo be releble. tt.ls
irUnded b'ustby per.ons hiW1g tectncellkl end It their OWl ck:nllon end rille .'Since an1t1ons ofua •• Clllslde our conrot, ..w
make no 'MTriet, e . - or implied., end -..ne ro 1-.1y in connec:tlon -..Ill 'fOI ue of this lntnn Ilion. Nolting henli'lls to be
taken es e.loense to opnte l.llder or • reconwnendlllan to lnthge ~ pattris.

455 Corporate Blvd., Newark, DE 19102 US.A.• Tel: 800-441..7m or 3112-456-4431• F•: 302-456-4444
www.f!!!l11kh!M!!!·COm .• E-Mel: [email protected]

60
 NASA!fM-2013-217910

IJESilia••
------

SCMU04 SOrf34()4. SCMMO~ Saof08

Sllcone Collllng Mllflkll tor Root i¥JP*alllon

SCM3402JSCM34WSCM3415/SCM3408 are on~part sllcone materials

specr~eal.,- desi!Jled for use In roofing applcations as the \lleatherseal coating
In silcone coated, spray applied urethane foam ro(tilg systems.
SCM34021SCM3404/SCM34051SCM3408 are specified for use Wlh roofing
granules i1 the top coat Wlen used In GE's ro(tilg system and applied by a
GE althorlzed applcator.

SCM 3402/SCM 3404/SCM 34051SCM 3408 are one COI'Jllonent materials

reqtirlng no rnxilg and can be applied by sprar,-, roller, or brush. Fast cure
rate, 15 to JO minute skinover time prOr'ides adequate time for grantie
apjjlcallon. 1·2 hour tack free time assures adequate cure al the end of the
apjjlcallon dart'.

The low SPraying viscosity of SCM 3402/SCM 3404/SCM 3405/SCM 3408

assures easy sprayilg with ai1ess spraroJ systems using a rnlni'num 25:1 ratio
air motor drllen pump. Cracks and gr~esfill easl.,-. High stallc viscosity
assures mal erial stays wt'lere It Is sprayed. It won't fbW otr high sp~s or
vertical areas on parapets.

SCM34021SCM3404/SCM34051SCM3408 are VOC COI'Jlll.iant. 200~1ter

mineral spiits content assures comJjlance In most areas (t California, grealer
New York City, New Jersey (Veri1Y complance In location of use).

61
NASA/TM-20 13-217910

I \I''' tll ' l i ttllttl ,,,,I Property Value Test

Oenllty, lbllgallon 10.45 WPSTMP·14
Color SCM3404 I Medium Gray Vltual to Standard
SCM3408 Dark Grly WPSTMC·1G
ISCM3405 Tan
ISCM3402 Whit
Solids Content, % by volume 65
%by weight 80
Tack Frte Time, houra
Sklnover Time, mlnutea
II 2
30
WPSTME-86
WPSTM c..seo
VIIIQOalty, c:entipolae 9000 WPSTMC..s80
Tenalle Strength, pel 200 ASTM D-412
!Elongation, % I 400 ASTM D-412
Peel Strength, lblllnch I 27 WPSTMC-628
Hardne•, Shore A I 32 I ASTM D-2240

Typical product data valuea ahould not be uaed 11 apeolficatlona. Alllatanoe

and apeclbtlona are available by contacting GE Silloonea at 8001255-8886.

® SIIPruf Ia a Reglatered Tredemark of General Electric Company.

TM UltraPruf ta a Tr1demark of Genel'll Electric Company.
®TEFLON II a Reglltered Trademark of DuPont.

Jn . ., ltttt I IIIII " l 11 1 I , , SCM3402/SCM3404/SCM34051SCM3408 may be applied by apreylng, rolling

or brulhlng to clean, dry, attucturelly tound aurr.ce.. For belt results ambient
temperature lhould be between 50 and 80 degreea F. Lower temperature a will
lengthen the al<lnover, tack free, and ultimata cure time, Higher temperature•
wllllhorten the cure time and working time for proper application of granulea
before the material haa lklnned. SUdden t mperature decllnea may alto result
In dew formation on aurr.oea whleh can prevent adhealon development. For
beat reaulta, relative humidity lhould be above 2QCM, , Lower humidity wilt alow
the cure l'lte algnlficantty.

Care lhould be taken to avoid overapray. All overapray lhould be cleaned up

Immediately and before It haa cured by wiping altematety ~h mineral aptnts
and dry raga. Cured material may have to be acraped off aurfacea with a razor
blade or ICNbbed off with lleel wool and mlnel'li aplrita. To oontrol overapray,
avoid apreylng In high winds (above15 mph) and/or malk allaurfacea which
are not to be ooated.

Cleanup of equipment oontalnlng uncured material may be accomplllhed by

fluahlng with mineral aptrtta. SCM3402/SCM34041SCM34051SCM34081hould
not be left In pumping equipment and ho~ea for prolonged perloda of time

62
 NASA/TM- 201 3-2 17910

unless all hoses are TEFLO Dned, aD piping connedions are sealed with
tenon and ad pump seals are teflon. SCM3402JSCM34041SCM3405/SCM3408
cures by reacting with moisture. Equipment without tenon fining and seals w· l
transmit sofficlent mo sture vapor to gradually form cured material on hose
waUs and at unsealed connections This may result In Increasing operating
pressures and material now restriction.

SCM3402/SCM3404/SCM34051SCM3408 are Identical products except for

color. \l\4len apply ng n two or more coats It Is advantageous to use alternating
colors to assure uniformity of coverage.

SURFACE PREPARATION

SCM3402/SCM34041SCM3405/SCM3408 may be applied over property cured,

&tructuraUy sound. dean and dry polyurethane foam. loose particles of foreign
matter should be blown, brushed or vacuumed away. Surface must be smooth
and ftat enough to prevent puddl ng of water on the nlshed roof. Large holes
should be patched with polyurethane foam, allowed to cure then ground oft
flush with adjacent surfaces. Smaller holes may be tilled with S IPr\11® or
UltraPrufTM sealants before application of the roof coating. Before applying
roof coating be sure surface also free of moisture and that at least 2 hours of
adequate temperature and humidity remain before the onset of n ghtfall or
inclement weather.

SCM3402/SCM3404/SCM3405/SCM3406 may be applied directly over each

other and over most other ilicone roof coatings. \Mlen reooating older licone
coated roofs be sure the surface Is clean, dry, structuraly sound and that al
holes and underlying damage has been properly repaired. The existing coating
may have to be power washed with an appropriate sorfactant solution then
power rinsed to remove dirt. It is recommended that a test patch be deaned
and coated with SCM3404/SCM3408 to vertfy the etrecttveness of the cleaning
process and the adhe&ion to the surface prior to beg rming the job.

SCM3402/SCM34041SCM3405/SCM3408 may be sprayed as received.

Additional dilution with solvent is neither necessary nor desirable. On
horizontal surfaces these materials may be sprayed easRy ln thicknesses up to
15 or 20 mils or more Without flowing or alliga oring.

Consult the GE SHicones Roofing System Suggested Speciftcatlons For New

or Retrofit Roofing , document 14549, for additional application information.

I l.1111llou~ .111tl '·"' 1\ Material Safety Data Sheets are available upon request from GE Silicones.
Similar lnfonnation for solvents and other chemicals used with GE products
should be obtained from your suppliers. Wlen solvents are used, proper safety
precautions must be observed.

63
NASA/TM- 20 13- 217910

'lot . l~t .uul \\.111.111 1\ The warranty period Is 6 months from date of sh pment from GE S cones If
•., nud stored In the orig'nal unopened container at 25•c (77•F) .

Products may be ordered rrom GE Silicones, wa erford, NY 12188, the GE

Silicones' sales office nearest you or where appropriate, an authorized GE
Sllcones' product distributor.

( o4•\ t I llllh I If ~~~till II\ lilt nt Prior to considering use of a GE Silicones' product in rut !ling any government
requirement, please contact the Government and Trade Compliance offiCe at
413-448-4624.

LEGAL OISO..AIMER

H£ MATERIALS PRODUCTS AND SERVICES OF GE SILIOONES, GE BAYER

SILICONES, GE TOSHBA SILICONES, THBR SUBSIDIARIES OR AFFILIATES (THE
"SUPPLIER'l, ARE SOLO SUBJECT TO THE SUPPLIER"S STANDARD CONDITIONS OF
SALE, VYHIOi ARE INCLUDED IN APPLICABLE SALES AGREEMENTS, PRINTED ON THE
BACK OF ACKNO'M.EOOMENTS AND INVOICES, OR AVAILABLE UPON REQUEST.
ALTHOUGH THE INFORMATION, RE<:OMMENOATIONS OR ADVICE CONTAINED
HEREIN IS GIVEN IN GOOD FAITli, SUPPUER MAKES NO WARRANTY OR GUARANTEE.
EXPRESS OR IMPLIED, (I) THAT THE RESULTS OESCRIBEO HERE WILL BE
OBTAIN ED UNDER END-USE CONOITIONS, OR (II) AS TO THE EFFECTIVENESS OR
SAFETY OF AnY DESfGN INCORPORATING SUPPLIER'S MATER! 5 , PRODUCTS.
SERVICES. RECOMMENDATIONS OR ADVICE. NOTHING IN THIS OR ANY OTHER
DOCUMENT SHALL ALTER. VARY, SUPERSEDE OR OP~TEAS A WAIVER OF ANY
OF THE SUPPLIER'S STANDARD CONDITIONS OF SALE.

Each user bears the full responstbillt)' for malong b own de1ermnatlon as to the su llillty of
Suppl r's matenats. produc:u. &eMOH. recommendatloOs or advice for its own parbCU r
purpo~e. Eactl utef' must tdettdy and pertorm t end analyses sufhctent to ass1Jf8 It that lt
finished parts WI be sate and SU4able ror use utu:ter nck.J oondlllonl Beeautie actual use
or ptOdUct$ by the uter beyond the control of Supptlet, such ute Is wit n ltte ~ctuslve
responSibl of the LIS«, and SUpplle cannot be held responSible tor any tor.s lncurred
through inc:orrect ()( raulty use ol the prodUCII$ Furt r. no It emenl contained herem
coooeming a PQ.Aible or ell of any m erial, prod\ld, RNK:e ()( dHign it ntended
or should be construed to grant any license under any patent or other lnletleclual propeny light
or SllP'Jiter or any of lis 5Ubsidta"" or a"lliated CXIIIlpeniel, « as a recommendation f« the
use olaucll meterilt~ Pfodud, ~ ()( deggn In the nringement of any 01 Olhe1
irltelledu property nght

64
 NASAffM-20 13-217910

·- -- -----------

Kartyte 11 eu,plt., _1a .. ,.,,,,

t~r

eo.,o-c AI( DO pow4er

C~t II A proprieUfJ IPOIIJ r ..la
COI!fO...l Ct . ~ rr.,r&.tUJ ..ly..Su aalM rMt.
TheKacertel Safat.1 hta AHta are provW.. Mparateb few Me~ of theM
cCM~PQMact. ,..... refer te theM •s•a few cbe lluar4a..,. Mfa 1M preper
hndUaa of o... ,,..., •.

n.ae c...-ce era evHll., 1a pre-,roportiou4 •lc• f• eur lieU uae.

Tile c.,ound c.. lie atall4 IIJ 11&1111 or whh - n •cllelltcel _ .. ._.. \lhea
freablJ ataetl the •t•r~ ra...a.lea • 4rJ, pwdery plaacar. It 1a eppUe4 lty
crowell-ala place, . .. rtrte prov14aa • vorkta& tiM, •r pet life, of epproxl-
•tdy U1r11 bolln a& ) ~ r, e., wUl cure c-.Jetalr w1cll1a ll lloauu et thla
. u.,.rarure ,

•
KartJtt ' ' .. eacreaa-c..,.retura ~••lataat coett.a vhtcll wee apectflcallJ
4evdo,H to tnaula&e rociLet aea&fJ __. ataatle l~YKII fr-• ... laat bMt,
ltleat eroet1111 _. relete4 4ec.e rJorettoa.
" A ,oceecul llaaar4 .., edat ia till IHUcet1• ..,. - o f cilia prollucc. hec
. creal., tidll a ~~~ cw lurtaa r.•v•l aM ruppUcaca.__.., ,,...., •
h•••r• t•&~ 1a tile vtclal&J vho are .., waarifta reeptretory pr•tectt••
ll •• ru-IWIH thee "' .,,..,... ••t rnp1Yatcw he IIM4 ta protect tiMt
..,loJ••fr• ,,,..,._ ,.rctcl••·

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NASA/TM-20 13- 21791 0

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