The new seven-story, 200,000-SF Headquarters is a gateway building and Central Campus hub for NASA’s employees at the Kennedy Space Center. This project was led by HuntonBrady as the prime consultant to NASA, with Jones Edmunds as subconsultant throughout all design and construction phases. Jones Edmunds provided site stormwater management system design and permitting, including modifications to the KSC Region 1 Stormwater Permit, utility infrastructure design including water, sanitary sewer, and stormwater utilities and paving and grading of new roadway connections and parking facilities. We provided NASA with follow-on construction administration services for Phase 1 of the new Headquarters building, Kennedy Data Center facility, and associated off-site infrastructure improvements. Jones Edmunds is also providing design services for Phase 2 of the project and has designed a new signalized intersection currently in construction at the main entrance to the Headquarters building off of NASA Parkway.
This project is part of a planned campus theme designed to replace the current Headquarters building and several other support buildings within the Industrial Area. The campus theme was developed during a Master Planning effort in 2010 led by Jones Edmunds with HuntonBrady as the Chief Architect and Planner supporting NASA. The Master Planning effort developed multiple new campus scenarios, each involving transportation, infrastructure, and facilities planning elements, ultimately arriving at the selection of the concept used in the current design and construction phases.
In alignment with NASA’s strategic goal to optimize capabilities and operations, KSC is in the process of divesting (demolishing) several obsolete and inefficient facilities. This project included the demolition of the old Headquarters Building (~440,000 SF) and Central Instrumentation Facility (~140,000 SF) and to reduce operational and maintenance costs at KSC. The project was also in support of the construction of the new Central Campus Complex.
The demolition task included supporting utility disconnections and alterations, hazardous material testing and coordination with NASA Environmental, and government support. The systems included water, wastewater, stormwater, gas, chill water, hot water, power, communications, and civil infrastructure. The design was coordinated with other improvements in the area to provide a seamless transition as NASA further develops the area into a Central Campus. During the construction phase, Jones Edmunds assisted NASA and provided industry expert support regarding PCB waste and disposal.
Jones Edmunds continues to provide engineering services during construction while the project shifts from the CIF demolition to the HQ Building demolition by reviewing shop drawings, responding to requests for information, attending construction progress meetings, making construction site visits, resolving unforeseen conditions, providing cost opinions, and will prepare as-built/record drawings.
The Crawlerway at the Kennedy Space Center is a 130-foot wide and over 4.2-mile long pathway between the Vehicle Assembly Building (VAB) and the two launch pads at Launch Complex 39. Natural soil and 3 feet of hydraulically dredged soil are below a 5-foot layer of compacted limerock, which lies beneath a 4 to 8 inch surface of Alabama river rocks, which were chosen for many properties, including hardness, roundness, sphericity and resistance to LA Abrasion. The Crawlerway was constructed in the early 1960’s and supported heavy space rockets being rolled to the launch pads throughout the Apollo and Shuttle Programs. Since the end of the Shuttle Program, heavy loads have not been traversing along the Crawlerway for many years and the Crawlerway soil foundation strength has waned and needs refurbishing and strengthening to support NASA’s next space program. By 2013, a project to repair and upgrade the Crawlerway was undertaken. It was the first time the foundation had been repaired since it was constructed. The limerock layer was increased by 2 inches, and the degraded river rock was removed and replaced with new river rock.
The Crawlerway was originally designed to support the weight of the Saturn V rocket and its payload, plus the Launch Umbilical Tower and Mobile Launch Platform (MLP), atop a Crawler Transporter (CT) during the Apollo Program. The total load to the ground was over 17 million pounds. The Crawlerway was also used from 1981 to 2011 to transport the Space Shuttles, also atop the MLP and CT, with a total load of 18 million pounds.
Jones Edmunds provided a study to evaluate the Crawlerway foundation for the transition from the Shuttle Program to NASA’s new heavy-lift vehicle, SLS. The Shuttle weighed 18 million pounds, and NASA’s new heavy-lift vehicle is expected to weigh over 26 million pounds.
The goals of this project included determining if the foundation could handle the increased load and performing a full-scale load test using a CT shoe to find the most suitable surface to use with the new heavy-lift vehicle.
We coordinated with several NASA organizations and their subconsultants to mobilize the load test apparatus, including Ames Research Center, Florida Department of Transportation, USACE ERDC, United Space Alliance, and EG&G. The load test required 500,000 pounds of weight vertically loaded onto the existing CT track shoe. A 250-ton “water bottle”, which NASA uses at the VAB to certify cranes, was used as ballast for the horizontal load. The load test included evaluating various gravel materials and resilient mats, while pressure cells were used to better understand distribution of the load under the CT shoe.
This project was awarded the 2011 Florida Section Project of the Year by the American Society of Civil Engineers.
Our civil design projects give us the opportunity to put our creativity to the test by identifying challenges and creating solutions for developing and effectively delivering quality and innovative designs and permitting, cognizant of time and budget constraints. Our vast knowledge of civil engineering systems helps create smart designs with a focus on functionality, ease of maintenance, and future growth. We help our government, aerospace, industrial, and federal clients with the services listed below: