Virgin Orbit UK Space Launch

• Project Scope In the dawn of a new era for aerospace in the United Kingdom, Virgin Orbit launched the maiden voyage for Spaceport Cornwall in January 2023. The task for ACA International…transporting everything required for a launch from various facilities in the United States to an overseas launch site, and then returning to the US after the completion of the launch. So how do you transport an entire rocket, ground support equipment (GSE), engines, replacement parts and propellants? ACA International worked with Virgin Orbit for over 3 years preparing and mapping out the necessary services, equipment and best routings needed for the round-trip journey. We chartered 747 freighters for the UK & US routes. Additionally, we worked along side the Royal Air Force loading/unloading and transporting the rocket and additional GSE on a C-17 from March Air Reserve Base, Riverside CA to the Spaceport in the UK. With no UK customs presence or ground handling services at the Spaceport, ACA coordinated closely with UK Border Force and area ground handlers to arrange timely clearances and unloading/loading of aircrafts. Before all this can happen, we worked closely with the airlines on load planning, including multiple pieces weighing over 10,000 LBS. The rocket and payload faring travel securely on specially designed sleds. However, these sleds weighing several tons must be secured properly to the aircraft floor and certified by the FAA for flight. ACA arranged the necessary “Fit Checks” with the airlines, and coordinated along side FAA inspectors during the actual inspection of the sleds inside the aircraft. What happens when not all the GSE is ready for transport on one of the chartered aircrafts or when engineers want to conduct an additional engine fit check prior to launch? ACA arranged several last-minute flights on scheduled freighters and passenger aircraft, facilitating the necessary door to door transport services. A large international aerospace project would not be complete without ocean transportation. With launch deadlines and carrier cutoffs approaching, along with limited vessel space, ACA booked and facilitated the door-to-door movement for several 20’ & 40’ containers including additional GSE, rocket propellant and hazmat containers originating from US fuel facilities. ACA arranged team drivers with proper port security credentials to deliver all containers from origin to multiple east coast ports. Propellants for space launch must regularly be tested for any degradation. ACA arranged transport of propellants to testing facilities in the UK and their return back to the Spaceport. When it was time to come home, the ACA team in the UK and US, again prepared the air shipments, charters, ocean sailings, necessary loading/unloading, domestic trucking including UK pick and delivery to various US locations, UK & US customs clearances, and the necessary onsite & onboard charter flight attendance by the ACA team.