United Launch Alliance (ULA), a prominent aerospace company, is bolstering its rocket transportation capabilities with a fleet of specialized cargo ships. These vessels are designed to efficiently move large rocket components from ULA’s manufacturing facilities to various launch sites.

RocketShip: The Workhorse Cargo Vessel

Currently, ULA relies on a single cargo ship named RocketShip to handle the transportation of oversized rocket parts. This specially-designed vessel has been instrumental in ensuring the timely delivery of components essential for ULA’s launch operations. RocketShip’s unique features allow it to safely and securely transport these critical pieces of hardware.

Built in 1999 in Mississippi, RocketShip began operating for ULA in 2000 under its original name, Delta Mariner. The vessel underwent an overhaul in 2019, during which it was renamed RocketShip. Measuring 312 feet long and weighing nearly 19 million pounds, RocketShip is a highly maneuverable ship capable of navigating both shallow rivers and open ocean conditions. It is the only U.S. flagged ship with this level of versatility.

RocketShip’s cargo hold is spacious enough to carry an entire Delta IV rocket, including three boosters, a second stage, fairing, and payload. The vessel transports rocket components from ULA’s 1.6 million square foot factory in Decatur, Alabama, located on the Tennessee River. From there, RocketShip navigates the Tennessee River, down the Mississippi River to the Gulf of Mexico, and then to Cape Canaveral, Florida or Vandenberg Space Force Base, California.

In the past, RocketShip has also made deliveries to other destinations, including Hawaii and Vandenberg Space Force Base in California via the Panama Canal. However, with the retirement of the Delta IV rocket from Vandenberg in 2022, the vessel will primarily focus on transporting the Vulcan rocket to Cape Canaveral.

SpaceShip: Expanding Delivery Capacity

To meet the growing demands of the Vulcan rocket program, ULA is constructing a second cargo ship called SpaceShip. This new addition to the fleet will significantly increase the company’s capacity to transport rocket components, enabling a more efficient supply chain. SpaceShip is expected to play a vital role in supporting the increased launch cadence anticipated with the Vulcan rocket.

ULA is partnering with Bollinger Shipyards in Louisiana and Bristol Harbor Group in Rhode Island to design and build SpaceShip. While specific details about the new vessel have not been released, renders suggest that it will closely resemble RocketShip in design and functionality.

The decision to expand its transportation fleet highlights ULA’s commitment to meeting the growing demand for its services, particularly from its largest customer, Amazon. The e-commerce giant has contracted ULA to launch its Kuiper satellite constellation, which aims to provide high-speed internet access globally. With the addition of SpaceShip, ULA will be better equipped to handle the increased launch rate required to deploy the Kuiper constellation in a timely manner.

Future Engine Recovery Ship

Looking ahead, ULA has unveiled concept art for an innovative ship designed to recover the engine section of the Vulcan rocket after splashdown. This unnamed vessel will be tasked with lifting the engine section from the ocean, marking a significant step towards reusability in ULA’s launch operations. By recovering and refurbishing the engines, the company aims to reduce costs and improve the sustainability of its rocket launches.

The Vulcan rocket’s first stage is powered by two BE-4 engines developed by Blue Origin. These engines, which run on liquefied natural gas and liquid oxygen, account for a significant portion of the rocket’s overall cost. By recovering and reusing these engines, ULA estimates that it could reduce the cost of the first stage propulsion by 90% and the total first stage cost by 65%.

Initially, ULA had planned to catch the engine section mid-air using a helicopter as it descended under a parachute. However, the company has since revised its approach to a more repeatable and less risky method. While details of this new recovery process have not been disclosed, ULA CEO Tory Bruno has stated that the company is actively working on developing the necessary technology and plans to implement engine reusability in the coming years.

Vulcan Centaur: ULA’s Next-Generation Launch Vehicle

The Vulcan Centaur rocket, ULA’s first new launch vehicle design since the company’s formation in 2006, is a critical component of the company’s future success. Developed to meet the evolving needs of both government and commercial customers, the Vulcan Centaur combines the proven reliability of ULA’s Atlas and Delta rockets with cutting-edge technologies and design improvements.

One of the most significant advancements in the Vulcan Centaur is its use of the BE-4 engine, which offers a substantial increase in performance compared to the Russian-made RD-180 engines used in the Atlas V. The rocket’s Centaur V upper stage, an upgraded variant of the Centaur III used on the Atlas V, further enhances its capabilities.

The Vulcan Centaur is designed to be a versatile and flexible launch vehicle, capable of delivering payloads ranging from small satellites to large interplanetary spacecraft to a variety of orbits. The rocket’s modular architecture allows for the attachment of up to six solid rocket boosters, enabling ULA to tailor the vehicle’s performance to meet the specific requirements of each mission.

Competing in the Launch Market

While the Vulcan Centaur represents a significant advancement in ULA’s launch capabilities, the company faces stiff competition from other players in the market, particularly SpaceX. The Vulcan rocket’s lack of full reusability may make it harder to compete on price with SpaceX’s Falcon 9 and the upcoming Starship mega-rocket, which promise lower costs per pound of payload.

However, ULA’s reputation for reliability, precision, and its ability to tailor the Vulcan rocket to specific mission requirements may give it an edge in certain segments of the market. The U.S. military’s policy of maintaining at least two launch providers and commercial customers seeking to avoid dependence on a single provider may also work in ULA’s favor.

To remain competitive, ULA is exploring ways to reduce costs and improve efficiency. In addition to the development of the engine recovery system, the company is investing heavily in modernizing its factory in Decatur, Alabama, and upgrading its launch facilities at Cape Canaveral. These investments aim to streamline production processes, reduce turnaround times between launches, and ultimately lower the cost of access to space.

Summary

United Launch Alliance’s commitment to expanding its rocket transportation fleet and developing the Vulcan Centaur launch vehicle demonstrates the company’s determination to remain a key player in the rapidly evolving space industry. By investing in specialized cargo ships like RocketShip and SpaceShip, ULA is ensuring a robust and efficient supply chain capable of supporting an increased launch cadence.

Moreover, the company’s pursuit of partial reusability through the recovery of the Vulcan rocket’s engine section showcases its dedication to reducing costs and enhancing the sustainability of its operations. While challenges remain, particularly in the face of competition from fully reusable launch systems, ULA’s focus on reliability, precision, and mission-specific adaptability positions it well to continue serving the needs of both government and commercial customers.

As the space industry continues to grow and evolve, United Launch Alliance’s strategic investments in transportation infrastructure, next-generation launch vehicles, and innovative recovery technologies will play a crucial role in shaping the future of space exploration and commercialization.