Delivers Largest-ever Space Science Observatory
Delivering the latest generation of space equipment into orbit is always a complex task, but for some of the largest pieces of cargo, delivery to the launchpad can be just as challenging as the journey beyond.
Heavy-lift specialist Rohde & Liesenfeld (USA) recently undertook one such project, delivering the giant James Webb Space Telescope (JWST), the largest-ever space science observatory, from a Northrop Grumman aerospace facility in Southern California.
“One of the main challenges involved finding a dock on the Southern California coastline that had the clearance of access from the shore side, considering existing road and bridge infrastructure as well as suitable protection from sea swell,” Jan-Ludwig Beringer, CEO of Rohde & Liesenfeld, told Breakbulk. “Equally important was finding a suitable dock with the height and fender design to allow for the transition of the telescope chamber from shore to ship.”
Adding to the complexity of the move, the high-precision JWST is extremely sensitive to atmospheric contamination, heat and sudden motion, meaning that the move had to be planned meticulously. To counter this, the unit was packed within a massive clean air chamber, but this still had to be moved without exposure to any undue vibration or g-forces and without extended exposure to the mid-day heat of the Southern California sun.
“Complex tasks such as this require patience and the expertise of many,” Beringer said. “Imagine a 10-hour ballet performance where every movement runs at 1/100th of the speed.”
Detailed Route Survey
Designed to orbit at 1 million miles from earth and operate at a temperature of -213 degrees Celsius, the JWST cost an estimated US$10 billion and was scheduled for launch in French Guiana, but first Rohde & Liesenfeld had to devise a suitable route to take the 332-tonne cargo to the coast for load-out to ocean vessel.
To ensure that all eventualities were considered, the firm partnered with specialist naval engineering firm Nordholm of Everett, Washington, based on "industry specific referrals, prior experience and creativity," to create a detailed route survey and identify potential locations to dock and receive the cargo.
“The dock structures and coastline were reviewed initially using google earth and then further validated with physical route surveys,” Beringer said. “Naval engineering and all plan designs were produced by Greg Nordholm PE using Autocad, and BlueBeam design construction software. All design review and planning sessions were undertaken between the parties using Microsoft Teams.”
Having reviewed the available options, the two firms identified the Naval Weapons Station Seal Beach as the best location, thanks to its proximity, security and dock-side infrastructure. This location also allowed the team to deliver the cargo by night convoy, avoiding the heat of the mid-day sun.
With the location set, the convoy departed from Redondo Beach under escort from California Highway Patrol vehicles and utility vehicles for wire lifting. Utilizing a remote-controlled steering axle trailer combination, the cargo traveled southbound at walking pace to avoid any undue vibration, transiting a closed-off portion of the 405 Freeway and several city streets. After several hours, the convoy arrived at Seal Beach at 4:30 a.m, just as the sun was rising.
“Transport of the telescope was undertaken using a specifically designed hydraulic multi-axle trailer with self-steering dollies that allowed for raising and lowering of the trailer to clear road obstacles and elevation changes and multi-directional movement of the trailer to circumvent tight corners,” Beringer said.
Floating Bridge Solution
Upon arrival at the dock, the team from Rohde & Liesenfeld then faced one of their biggest challenges – transferring the giant structure onto the nearby roll-on/roll-off vessel Colibri. Purpose-built vessel to transport aerospace components, the Colibri comprised a watertight garage the size of a football field, but as before the team had to avoid even the slightest vibration when moving the precious cargo.
As a result, Rohde & Liesenfeld and Nordholm devised an ingenious solution that involved building a floating bridge, connecting the Colibri with the shore. This design comprised a stationary spud barge, with legs extending down into the seabed, combined with a flat-deck floating barge connected to the navy’s pier using a series of engineered steel ramps.
“Specifically engineered and designed steel interlocking ramps supplied by Nordholm Co. were used for the transition between the dock wall at Seal Beach and the Eel Point flat-deck barge to accommodate both the span and overall load-bearing required for the travel of the telescope from shoreside to seaside and from barge deck into the ro-ro vessel Colibri,” Beringer said.
This design delivered a one-inch tolerance in relative list, allowing the team to compensate for tide changes and wind as well dampening any excessive acceleration or deceleration g-forces of due to rolling or pitching from sea swell.
Under the supervision of NASA’s scientists and business unit managers, the telescope was then rotated 180 degrees to position its stern end to the stern ramp of the Colibri using the same steerable multi-axle trailer and tractor unit it had arrived on.
With everything in position, team carefully walked the giant cargo from the EEL Point barge up the ramp of the vessel and secured it safely in the hold of the Colibri, in preparation for its onward journey to French Guiana. Travelling 9,300 kilometers aboard the through the Panama Canal to Port de Pariacabo on the Kourou River, the cargo arrived in French Guiana safely and is scheduled to launch from the European Space Agency’s spaceport on Dec. 18.
Rohde & Liesenfeld (USA) is part of Canadian project cargo group Rohde & Liesenfeld which operates a network of offices and air and ocean hubs in over 50 countries. R&L is a member of the Canadian International Freight Forwarder's Association and the Specialized Carriers and Rigging Association.
Video and Content Links Related to the James Webb Space Telescope Project
The Webb Telescope Journey to Space: Loading and Departing
How to Ship the World's Largest Space Telescope 5,800 Miles Across the Ocean
JWST Discharging at Kourou
The Webb Telescope Journey to Space: Unpacking in the Cleanroom
Photos and Video Links CREDIT: Jan-Ludwig Beringer, Rohde & Liesenfeld
