Space Shuttle Crawler Transporter Truck Shoe Qualification Tests and Analyses for Return-to-Flight

A vital element to Launch Complex 39 (LC39) and NASA's Kennedy Space Center (KSC) mobile launch transfer operation is a 3 million kilogram behemoth known as the Crawler Transporter (CT). Built in the 1960's, two CT's have accumulated over 1700+ miles each and have been used for the Apollo and the Space Shuttle programs. Recent observation of fatigue cracks on the CT shoes led to a comprehensive engineering, structural and metallurgical evaluation to assess the root cause that necessitated procurement of over 1000 new shoes. This paper documents the completed dynamic and compression tests on the old and new shoes respectively, so as to certify them for Space Shuttle's return-to-flight (RTF). Measured strain data from the rollout tests was used to develop stress/loading spectra and static equivalent load for qualification testing of the new shoes. Additionally, finite element analysis (FEA) was used to conduct sensitivity analyses of various contact parameters and structural characteristics for acceptance of new shoes.