While the concept of space travel conjures images of sleek, futuristic spacecraft, the reality often involves repurposing existing infrastructure. Think of Star Wars’ Millennium Falcon, rather than Star Trek’s starship Enterprise.
Historically, launch pads have been purpose-built for specific launch vehicles. However, the rapid expansion of the modern commercial space industry is driving a cost-focused shift from building entirely new facilities to retrofitting existing ones. Preparing a launch site represents an enormous startup cost that can appear overwhelming to emerging launch companies. The retrofit approach offers significant cost savings and enables quicker deployment of launch capabilities for the next generation of spaceflight.
From Purpose-Built to Retrofit
The initial era of spaceflight saw massive investments in purpose-built launch facilities tailored to specific vehicles and missions. The Apollo program, for example, involved significant investment in infrastructure that was highly specialized for the Saturn V and future, larger launch vehicles. Similarly, intercontinental ballistic missile (ICBM) launch facilities were designed for their unique operational profiles. Once these programs concluded, the existing infrastructure remained. Meanwhile, funding for new construction was often unavailable or exceptionally difficult to obtain. This has led to the practice of retrofitting existing facilities for new uses.
Early launch vehicle advancements often involved incremental improvements to existing technology, utilizing similar fuels and thereby enabling reuse of existing infrastructure, storage tanks and launch towers. However, the current generation of launch vehicles presents new challenges. The transition to new fuels and engine configurations — such as using more, smaller engines instead of fewer, larger ones — often requires significant modifications to use existing launch infrastructure.
Furthermore, the launch cadence driven by the commercial space industry is increasing at an unprecedented pace, placing additional stress on existing infrastructure, coupled with intense cost pressures.
Figure 1: United States-based orbital launches by year.
Strategies for Successful Retrofitting
Much planning and work goes into retrofitting an existing launch site to prepare for launching newer rockets. Sometimes the simplest solution is to bulldoze the site and start over, but first, it is important to consider how parts of the existing facility might be utilized and merged with new construction to save money. Not every component may need to be replaced.
For example, commercial space firms have taken over launch sites with existing elevated approaches and thus only need to build a new flame duct and launch stand. This means the organization will not need to rebuild everything, allowing it to start launching sooner. Building adjacent to an existing pad within a site can be another option that takes advantage of the zoning, permits and acreage already associated with the legacy launch site.
Building at a legacy site can also offer logistical advantages in terms of existing access roads, utilities and stormwater systems, especially since these sites tend to be in fairly remote locations. Careful planning considers all aspects of potential usage to derive maximum benefit from repurposing and retrofitting.
The commercial space industry has two additional options it can consider to spread or share costs:
- Multiuser launch sites. Whether within the same boundary or on adjacent tracts, it can be beneficial to collocate facilities. By sharing infrastructure — and potentially the permitting — developers can minimize duplication and streamline the process, enhancing their speed to market and further reducing costs. This has been done successfully by the Virginia Spaceport Authority at its Mid-Atlantic Regional Spaceport at Wallops Island.
- Multiple launch sites. Another way to increase flexibility is by having easily transportable launch systems with portable components, such as the transport erector, or ways to tie into common attachment points so different launch stands can be used. This allows the company to potentially launch from different sites without having to duplicate everything. These efficiencies can make different geometries work for each vehicle.
Navigating New Challenges and Considerations
The new generation of launch vehicles brings both opportunities and challenges. Numerous elements go into successful planning for a retrofitted launch pad:
- Adaptable launch pad design. Modern launch pads can be designed to be flexible enough to accommodate a variety of launch vehicles and mission profiles. This calls for modular designs and adaptable infrastructure that can be easily reconfigured. Key design considerations should include ease of access for maintenance and upgrades, as well as safety features to protect personnel and equipment.
- Thermal and acoustic mitigation strategies. Many new rockets can generate significantly higher thermal and acoustic loads than their predecessors. Mitigation strategies protect the launch pad infrastructure and the surrounding environment. This might involve advanced insulation materials, acoustic barriers and specialized cooling systems.
- Safety and regulatory compliance. Adherence to safety regulations and best practices is paramount throughout the retrofitting process. This includes rigorous inspections, comprehensive risk assessments and strict adherence to all relevant codes and standards. The upcoming NFP 461 standard, expanding on existing code to develop new fire protection guidelines for spaceports and users at adjacent sites, will have a significant role to play upon its release in 2026.
- Environmental considerations. Retrofitting projects must also address environmental concerns, including stormwater management, air quality and potential impacts on local ecosystems and communities.
Moving Toward the Next Horizon
Retrofitting launch pads presents a cost-effective solution to leverage legacy infrastructure and support the growing commercial space industry. By adopting adaptable designs, implementing robust mitigation strategies and prioritizing flexibility, spaceport authorities and launch companies can maximize cost and schedule efficiency while minimizing impacts and giving new life to aging infrastructure. Retrofitting existing launch infrastructure is a crucial step in that direction. The next era of spaceflight will be defined not by how much new infrastructure we build, but by how wisely we reinvent what we already have.
When your business is lean and your goals are big, your only choice is to pioneer something new. Learn how Intuitive Machines developed a new propulsion testing facility for its lunar lander engine.
