United Launch Alliance Beyond Gravity Warehouse

The Challenge

The construction of the United Launch Alliance (ULA) and Beyond Gravity and Finished Goods buildings required innovative solutions and close collaboration to overcome several obstacles. Beyond Gravity, a world leader in composite technology for payload fairings, needed new state-of-the-art buildings on ULA’s Huntsville campus. Barge Design Solutions’ (Barge) project scope included a 310,000-square-foot warehouse for materials receiving and finished goods and a 250,000-square-foot production building with advanced structural designs, office spaces, and storm shelters.

During the construction process, severe weather caused the collapse of a steel framework section. The damaged section consisted of a single bay with 225-foot trusses and a 65-foot clear height, presenting recovery challenges. The Finished Goods building added further complexity, as it had to support an 84-ton underhung bridge crane suspended from 300-foot roof trusses with a 62-foot clear height. Simultaneously, the COVID-19 pandemic disrupted supply chains, delaying critical materials.

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The Solution

Barge acted swiftly to address these challenges. After the storm-induced steel collapse, they assessed the damage, revised engineering plans, and expedited the fabrication of replacement materials while reinforcing bracing systems to mitigate future risks. Advanced structural modeling and close coordination ensured the bridge crane's significant load requirements were safely accommodated. Proactive supply chain management, including early procurement of long-lead items, minimized delays caused by pandemic-related disruptions.

The Result

Despite the challenges, the project was completed successfully, on time and under budget. The new buildings provide cutting-edge infrastructure for manufacturing rocket components, supporting the vital work of protecting payloads during launches. These buildings stand as a testament to adaptive construction practices and stakeholder collaboration, advancing the mission of ULA and Beyond Gravity.

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