Houston, Texas

Between August 2003 and May 2006 Conservation Solutions, Inc. (CSI) stabilized and restored the Saturn V Rocket located at the entrance to the Johnson Space Center (JSC), Houston, TX. This Saturn V rocket is one of three surviving vehicles built during the late 1960s to launch Americans to the moon. The JSC Saturn V is designated a National Historic Landmark and it is distinguished from the others as being assembled from flight-ready stages and spacecraft abandoned after cancellation of the Apollo and Skylab programs. Measuring 363-feet-long (the Statue of Liberty is approximately 60 feet shorter, even when including its base) and capable of generating 7.5 million pounds of thrust, the Saturn V remains the largest, most powerful American launch vehicle ever built.

Displayed outdoors and on its side since 1977, the rocket was exhibiting widespread paint failure, moisture infiltration, structural failures, an overall accumulation of atmospheric and biological soiling, and severe corrosion of its complex system of metal alloys, including aluminum (extruded, cast and milled) and aluminum honeycomb sandwich. Non-metal materials such as spray-on polyurethane foam, cork, and various types of plastic, phenolic resin, and fiberglass composites, had significantly deteriorated.

Assessment & Testing

CSI evaluated the rocket through a thorough conditions assessment and testing phase from January through August 2004. A visual and hands-on survey by CSI conservators, a structural engineer and a corrosion engineer was conducted from the ground and from a 60 foot articulating manlift. Select access panels and tunnel covers were removed to probe interior systems and fuel tanks. The interior of the Service Module and the Command Module were accessed for inspection only after they had been lifted and removed from their display stands. Observed conditions were thoroughly photographed and noted onto AutoCAD drawings produced by CSI for the survey.

The purpose of the testing program was to assist in determining the condition of materials present, identify root causes of observed deterioration, and provide appropriate methods of intervention and repair to reduce or arrest the rate at which the materials were deteriorating. Throughout the assessment, representative material samples were removed from the vehicle for testing including paint layers, powder corrosion products, and microbiological specimens. On- and off-site testing was performed to determine the safest and most successful methods to remove coatings, corrosion, soiling, surface contaminants (salts) and repair losses. The assessment report, which included an analysis of observed conditions, results of testing, and recommendations for repairs, was submitted for review by a panel of specialists designated by the Smithsonian Institution.

The specific treatments recommended for this rocket were based on the premise that, as part of this contract, CSI would oversee the construction of a climate controlled building over the rocket prior to the commencement of the restoration.

Treatment

Paint coatings and loose corrosion products were removed using high pressure waterjets (>25,000 psig). More fragile materials were stripped of coatings using chemical gels. Corrosion was treated by mechanical removal and/or the use of chemical metal brighteners. Metal failures were repaired in-kind with new aluminum, body fillers, as well as replication of non-structural replacement parts with molded fiberglass. Structural repairs were designed by engineers and installed to return structural stability to significant features including F-1 and J-2 engines, Stage II Thrust Structure, and the Service Module. Modified and new display stands components were designed for the Service Module and Command Module/Launch Escape System. The water saturated and severely deteriorated exterior foam insulation of Stage II was slowly air-dried, losses were filled with new foam planking, and the entire stage was wrapped with a paintable geo-textile. After all repairs were complete, the rocket was primed and painted to match the historical color and scheme determined through paint analysis. Matching decals were custom made and installed over the paint system.

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Articles about the restoration of Saturn V at the Johnson Space Center are listed below.

“Houston, We have a Restored Moon Rocket”, Space.com, July 20th, 2007

“NASA sets Grand Opening July 20th Opening for Restored V Rocket”, Nasa.com, July 10th, 2007

“Working to Save Houston’s Saturn V Moon Rocket“ SpaceflightNow.com, April 6th, 2004