Modification of the Ares-1 Mobile Launch Space System

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Year:

2016

Location:

Kennedy Space Center

Summary:

Electrical Cable Installation
Electrical Test Plan Creation & Implementation
Electrical Hardware Logistics

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Ares-1 SLS Modification

In 2016, Core Electric was honored to support NASA’s modernization of the Ares-1 Mobile Launch Space System at Kennedy Space Center—an ambitious and technically demanding effort requiring precision, adaptability, and deep knowledge of launch support infrastructure. Our team was tasked with a combination of electrical cabling installation, electrical testing, test plan creation, and logistical coordination to ensure the readiness and integration of systems critical to future spaceflight operations.

This project served as a key step in repurposing and modifying the existing mobile launcher infrastructure that had been originally developed for the Ares I rocket. As part of the evolving launch architecture for NASA’s Space Launch System (SLS), the work involved not just building new systems, but reshaping and validating old ones to meet new demands.

Our first area of focus was electrical cabling installation—a job that demanded the careful routing and termination of high-performance cabling across one of the most complex launch platforms in the world. The Mobile Launch Platform (MLP) spans multiple levels, including the umbilical tower, support structures, and mobile base, each with unique operational and environmental considerations. We installed extensive power and signal cabling for critical control systems, instrumentation, lighting, and telemetry pathways—ensuring every run adhered to rigorous standards for heat, vibration, EMI shielding, and physical durability.

Because the system operates in close proximity to launch vehicle ignition, environmental conditions are extreme. We used fire-rated cables, heavy-duty conduit, weather-sealed enclosures, and vibration-dampened mounting solutions designed specifically for launch pad environments. Every routing decision had to account for physical safety, redundancy, and serviceability, all while preserving integration pathways for evolving systems.

Parallel to installation efforts, we developed and executed a detailed test plan to verify system functionality, performance thresholds, and interconnectivity. Our engineers collaborated with NASA and prime contractors to define logical test sequences for both powered and passive systems. These test plans covered a range of scenarios, including continuity testing, insulation resistance testing, grounding validation, and system-level functionality checks. The plans were designed to allow phased verification as systems came online—mitigating risk, reducing delays, and ensuring that every subsystem was operating within spec before being handed off to integration teams.

In addition to the hands-on work, our team was responsible for logistical coordination across various trades, contractors, and oversight personnel. A project of this scale involved multiple stakeholders—from structural teams and automation engineers to safety inspectors and NASA operations staff. We scheduled our work in tight alignment with other site activities to ensure no interference or duplication of effort. This required constant communication, real-time documentation, and adaptability to changing field conditions.

The electrical testing phase was executed with military-grade discipline. Every cable was tagged, terminated, and tested using calibrated instruments. Documentation was created for each run, including resistance values, insulation results, and end-to-end validation data. Any anomalies were logged and corrected immediately, with secondary validation performed by QA personnel.

This project exemplifies Core Electric’s capability to operate at the intersection of advanced technology, rigorous compliance, and aerospace-grade reliability. We are proud to have played a part in laying the groundwork for NASA’s next generation of manned missions, helping to shape the infrastructure that supports the journey to the Moon, Mars, and beyond.