Complex 40 / LC-40
In 1998, as a result of USAF’s decision to implement the Evolved Expendable Launch Vehicle Program (now called the National Security Space Launch program) at CCAFS, the 45th Space Wing initially decided to deactivate LC-40 and place it in a “pre-demolition” state. However, in 2007, the 45th Space Wing decided to renew the complex for use by SpaceX. SpaceX’s proposal to revitalize LC-40 was analyzed in a 2007 USAF EA (USAF 2007). Since then, SpaceX has conducted refurbishment of and upgrades to the existing support buildings and launch pad to bring LC-40 back into operation as a launch facility for the Falcon launch vehicle program.
In addition to Falcon launch operations, the 2007 USAF EA included construction of a new hangar facility with supporting systems, as well as Dragon reentry. At the time, SpaceX’s goal was to conduct 8 to 12 launches per year for both the Falcon 1 (no longer in operation) and Falcon 9. All flights were expected to have payloads, including either satellites or Dragon.
In 2011 and 2012, SpaceX constructed a hangar annex and support facilities. Launch pad and facility modifications also were accomplished. The potential environmental impacts of this construction were analyzed by the 45th Space Wing. In 2013, a supplemental EA was prepared to expand on the action analyzed in the 2007 USAF EA to include operation of an upgraded Falcon 9 (referred to as the Falcon 9 version 1.1. [v1.1]). The FAA was a cooperating agency in the preparation of the 2013 USAF SEA. The Falcon 9 v1.1 was similar to the vehicle design of the Falcon 9 (Block 1), except it was taller, heavier, and had more thrust due to a newer model of the rocket’s Merlin engine. The Falcon 9 v1.1 was a medium-lift class launch vehicle with a gross lift-off weight of approximately 1,100,000 pounds. The Falcon 9 v1.1 used the same propellants as Block 1: liquid oxygen (LOX) and highly refined kerosene (RP1).
As of October 2019, SpaceX has launched the Falcon 9 vehicle from LC-40 46 times. One anomaly occurred in June 2015 when, approximately 139 seconds into flight, the second stage exploded over the Atlantic Ocean. After assessment of operations, SpaceX successfully launched the Falcon 9 with 11 ORBCOM satellites in December 2015. Another anomaly occurred when LC-40 was heavily damaged following the September 2016 catastrophic failure during a static fire test. The complex was repaired and returned to operational status in December 2017.
Now known as SLC-40 and SLC-41, these complexes were built as part of an Integrate-Transfer-Launch (ITL) facility and are located at the north end of CCAS. The primary facilities in the ITL area include the Vertical Integration Build (VIB) (where the core vehicles and payloads are assembled); the Solid Motor Assembly Building (SMAB) (where the solid motors are built up from their individual segments); the Solid Motor Assembly and Readiness Facility (SMARF) (where the core vehicles and the solids are mated); and the pad’s themselves. When these facilities were initially constructed in the early 60’s, they supported the TITAN IIIC vehicle. Since that time, and with required upgrades, they supported the TITAN 34D and TITAN IV.
The Cape's TITAN IIIC construction program began in earnest on 24 November 1962 after a $4.6 million contract was awarded to the Atlantic Gulf and Pacific Company to prepare sites for launch complexes 40 and 41. Though the timetable for completion of the pads remained "soft" for several months, both complexes had to be connected to other facilities in the TITAN IIIC Integrate-Transfer-Launch (ITL) system via railroad lines across a shallow area in the Banana River.
Since much of the land selected for other ITL facilities was also covered by shallow water, most of the area had to be built up, and dredging operations were underway by February 1963 to move 6.5 million cubic yards of landfill from the Banana River to the ITL sites. The contract for the TITAN IIIC launch complexes was awarded to C. H. Leavell and Peter Kiewit & Sons on 13 June 1963, and it was completed in 1965 for approximately $17 million. A $479,500 contract for the TITAN IIIC railroad (i.e. an extension of the NASA railroad network) was awarded to B. B. McCormick, Inc. on 30 July 1963, and it was completed in 1964. Most of the other ITL facilities were grouped under a $26.8 million contract awarded to the firm of Paul Hardeman and Morrison-Knudsen on 30 July 1963. That contract was completed on 16 April 1965.
Since the Air Force intended to use Complex 40 for its Manned Orbiting Laboratory (MOL) flights, Complex 41 eventually supported all the TITAN IIIC missions launched from the Cape between the beginning of 1967 and the end of the decade.
The Akwa-Downey Construction Company began building Complex 40's MOL Environmental Shelter shortly after the second TITAN IIIC mission in October 1965. The Shelter was ready for beneficial occupancy by the middle of June 1966, and American Machine and Foundry completed installation of the Shelter's work platforms two weeks later. A modified GEMINI capsule was launched from Complex 40 as part of an experimental mission on 3 November 1966. That capsule had been launched and recovered during the GEMINI 2 mission, but it was modified by the McDonnell Aircraft Company to perform a heat shield test for the MOL program. The modified capsule was installed in the MOL Environmental Shelter on 3 October 1966, and it was launched with the rest of the TITAN IIIC's payload one month later.
Though the MOL program was terminated in 1969, the Shelter was modified to accept new TITAN payload fairings, and the "new" Shelter began supporting TITAN IIIC launch operations when flights resumed at Complex 40 in April 1970.
No TITAN IIICs were launched in the last half of 1969, but two TITAN IIIC missions lifted off Complex 40 in 1970. The first of those two flights concluded the VELA detection satellite launch program by boosting ARPA's 11th and 12th VELA satellites into orbit on 8 April 1970. The other flight took place on November 6th, and it involved a classified DOD payload. Complex 40 continued to be used for classified missions during the 1970s and 1980s.
In the 1970s, TITAN IIICs were launched only from Launch Complex 40, and they were used to place satellites into very high, geosynchronous equatorial orbits. To accomplish this, the "Cs" were equipped with a standard liquid core, two strap-on solid rocket motors and a liquid-fueled transtage. The TITAN IIIC's core and solid rocket motors were identical to the ones used on the TITAN IIID. The last TITAN IIIC lifted off Complex 40 in March 1982, followed by the first TITAN 34D on 30 October 1982.
In the spring of 1990, Martin Marietta was awarded a major contract to upgrade Complex 40 into a TITAN IV launch site. Martin Marietta, in turn, awarded a $100 million subcontract to Bechtel National, Inc. in early June 1990 to cover the remaining design, procurement and construction effort. The project included a new Mobile Service Tower (MST), a new Umbilical Tower (UT) and supporting systems. Both new towers were designed with a high level of corrosion resistance in mind, and the UT was built stronger to handle the heavier SRMU loads anticipated in the near future. The old UT was completely demolished by the end of August 1990, and MST demolition was ahead of schedule. Reconstruction was a monumental task: the new 265-foot-tall MST contained 21 working levels and the 170-foot-tall UT contained 15 working levels. A new Air-Conditioning Shelter (ACS) was equipped to handle all projected requirements for the new TITAN IV, its CENTAUR upper stage and payloads. Launch pad modifications extended to fuel and oxidizer waste tank containment areas, security systems and the fuel vapor incinerator area.
The new UT was completed in the fall of 1991, and the new MST was completed in April 1992. All aerospace ground equipment was installed by the spring of 1992, but the launch facility experienced crane test failures in April, and electromagnetic interference (EMI) leaks were discovered around Complex 40's EMI doors. The leaks were repaired, but four doors failed independent EMI tests in August 1992. Martin Marietta was compelled to develop recovery plans for the EMI condition, which became the "driver" in delaying completion of the project. By mid-October, the problem pushed Complex 40's initial TITAN IV launch capability to 1 December 1992. New "finger stock" passed high frequency and low frequency tests in November 1992, and that stock was installed on 55 EMI doors in December 1992. Air-Conditioning Shelter enhancement continued into the early part of 1993, and Complex 40 received its first TITAN IV/CENTAUR launch vehicle on 2 June 1993. That vehicle was launched successfully on a MISTAR communications satellite mission on 7 February 1994.
