Port and factory expansions pave the way for the future development of Space Coast

The space facilities around Cape Canaveral on Florida’s east coast are undergoing significant upgrades and expansions in preparation for an increase in spaceflight activity. These developments include the construction of new launch pads, upgrades to processing facilities, and expansions to factories and Port Canaveral itself. These improvements are necessary to accommodate the upcoming generation of reusable rocket stages, such as SpaceX’s Starship and Blue Origin’s New Glenn.

A recent flyover conducted by NSF’s Max Evans and Julia Bergeron provides insight into the progress of these upgrades and hints at the future flight activity in the area. SpaceX has resumed work on the Starship launch facility at the Kennedy Space Center’s Pad 39A, indicating progress in the development of this spacecraft. Blue Origin has also been conducting tests on its second stage hardware.

Relativity is working on its launch facility for the Terran R vehicle, while NASA is focusing on the construction of the Mobile Launcher 2 (ML-2) for the SLS Block 1B. Airbus is expanding its factory in the area to accommodate increased satellite production. Finally, Port Canaveral has plans to build additional facilities to support spaceflight activities, including Blue Origin’s barge for New Glenn landings.

SpaceX has not only resumed work on the Starship pad but has also upgraded its current launch infrastructure for Falcon family vehicles. The company has added new liquid oxygen tanks to increase flexibility in recycling countdowns for Falcon Heavy missions. The SpaceX payload processing facility at Cape Canaveral has also received upgrades, including a fresh coat of paint. Expansion work has been carried out at the Roberts Road facilities, which will support the future development of a Starbase facility in Texas.

Elon Musk, SpaceX’s CEO, has stated that the company plans to begin Starship operations at the LC-39A facility in mid-2025. As a result, significant additional work is expected to be carried out on the Starship launch tower and pad in the coming months. Two additional Starship launch facilities are planned for Florida, along with two in Texas, which will greatly increase Starship’s launch cadence once completed.

Blue Origin’s Exploration Park facility is also undergoing expansion. The new Composite Assembly Building, which will become the Lunar Assembly Facility, is being constructed, and additional land surrounding the building is being prepared for future development. Preparations for New Glenn’s first flight, scheduled for the end of this year, are progressing, with hardware being tested at the 2CAT building.

Relativity is actively working on its launch facility at LC-16, preparing it for the upcoming Terran R launch vehicle. The company is performing foundation work for the horizontal integration facility and adding water lines to the launch pad. Airbus, on the other hand, has purchased Eutelsat OneWeb’s stake in the Airbus OneWeb Satellites joint venture and is now the sole owner of the factory across from Blue Origin’s Exploration Park. The factory is currently capable of building two satellites per day and is undergoing expansion to meet the growing demand for small satellites.

NASA has contracted Bechtel to build the ML-2 launch platform for the SLS program. Construction work has been underway since August 2023, with the base of ML-2 being lifted by self-propelled modular transporters. After completion, a launch tower will be built on the platform to support SLS Block 1B launches starting with Artemis IV.

Port Canaveral has been a hub for marine activity related to spaceflight, including SpaceX’s recovery of Falcon 9 boosters and fairings. With the expected increase in launch and landing activities by SpaceX, Blue Origin, and other companies, Port Canaveral is planning expansions to accommodate this growth. Space Florida has commissioned a feasibility study to explore various expansion options that could cost up to two billion dollars to complete.

These expansions include proposals to expand the middle turning basin to the north, create a dedicated wharf near LC-34, and expand the west turning basin. The objective is to handle the anticipated exponential growth in spaceflight traffic over the next few decades. The first phase of expansion will not disrupt the existing infrastructure, but later phases will require the relocation of roads and the construction of new channels and berths. Space Florida is conducting long-term and short-term studies to determine the best course of action.

While attention is often focused on launches and spacecraft, the daily work on facilities, their maintenance, and upgrades are essential to ensure successful missions and ongoing space exploration. As new launch vehicles enter service, such as Starship and New Glenn, the launch facilities, processing facilities, factories, and port facilities in Cape Canaveral will continue to be upgraded and expanded to meet the demands of a growing industry.

(Article Credit: NASASpaceFlight.com)