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Raven Report No. R0184-002

SPACE SHUTTLE INFLATABLE TRAINING ARTICLES

Final Report for

Contract NAS 9-16854

Submitted to:

National Aeronautics and Space Administration L}~don B. Johnson Space Center

Bouston, Texas

20 February 1984

Prepared by: )

~~.A' ~. /_ /~/. ~~~~~.~ ~~~. ~~~.,

Mark (L. West Project Engineer Appli.ed Technology Division·

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Vice President Applied Technology Division

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Raven Report No. R0184-002

NASA FINAL REPORT

Table of Contenta

1.0 Design Summary

1.1 LDEFl

1. 2 STT A

2.0 Object Utilization

3.0 Appendices

A - LDEFl Proposal

B - RBADS 1161

C - Material Test Results

D - LDEFl Drawing Package

E - Torus Construction

F - STTA Proposal

G - S'l"l'A Alternate Sizing Analysis

B - STTA Alternate Configuration Analysis

I - S'l'TA Drawing Package

J - LDEFl and STTA Service Manual

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Raven Report No. R0184-002

Final Report for NASA Contract 9-16854

SPACE SHUTTLE INFLATABLE TRAINING ARTICLES

This report concludes contract NAS 9-16854 which included the design, development, construction and testing of the Long Duration Experimental Facility Inflatable (LDEFI) and the Space Telescope Training Article <STTA). Both articles are similar in nature, materials and construction techniques but vary widely in shape and have unique problems affecting size, shape, gross/net lift and balancing.

1.0 DESIGN SUMMARY

1.1 Long Duration Experimental Facility I~flatable

The final design of the LDEFI varied little from the design submitted in the original proposal (Appendix A). The basic variations were in the following areas: Material, end fittings and inflation port construction.

The material used was a 70-denier polyester with a count of 103 x 103 and a weight of 2.0 oz. per yard. This material was coated with .15 oz. of adhesive followed by .25 oz. of aluminized urethane on the outer surface and .25 oz. of adhesive followed by 2.0 oz. of white urethane which served as a helium barrier. This material was deSigned to meet the specifications set forth in RBADS 1161 (Appendix B). The test reports (Appendix C) show the results as tested to this specification.

The skirts and end panels were made of a nylon material similar in weight and strength to Dacron. The outer surface had .15 oz. of adhesive covered with .35 oz. of silver. No coating was placed on the reverse side.

The end fittings were redesigned to a larger diameter to allow the material to be tucked less as it was secured to the spool. The actual end fitting can be seen in drawing C-S1621 in Appendix D.

The torus was originally to be connected to the main envelope by a series of three inch tabs glued to the torus and the main envelope where they intersected. This proved impossible, and a system of Velcro straps was devised instead. Details of this may be found in draw ing D-51642 in Appendix D.

To define size, several prototypes were constructed to determine elongation under biaxial pressure. Uniaxial stress/strain and creep proved' invalid due to the mechanics of elongation ,of the woven fabric. The torus lay-flats were

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Raven Report No. ROl84-002

not reduced in size in the warp direction but were reduced by 6.5% in the' fill direction. The envelope size was increased in the warp direction by 2.0% and decreased in the fill direction by 3.7%.

The apparatus was constructed in accordance· with the drawings in Appendix O. Very few problems occurred during the construction, and most were remedied by adjusting the assembly method or technique. The technique for fabricating the tori is detailed in Appendix E.

1.2 Space Telescope Training Article

The final design of the STTA varied greatly from the original design submitted in the proposal (Appendix F). There were several reasons for this.

First, the original weight distribution in the RFP called for two pounds at each hard mount. As a result, 39 pounds were placed within 41 inches of the forward end of the aft section. A study was conducted to determine whether other shapes could compensate or whether the dimensions of the forward and aft section should be changed (Appendix G).

It was determined that, by shortening the forward section by 5.5 feet and adding that amount to the aft section, the hard mounts were shifted closer to the center of buoyancy of the aft section. The object now could be balanced and buoyant.

Second, several potential problems were discovered in the fabrication of the LOEFI, and it was decided that the unsupported outer skin was not practical for reasons of appearance and sealability. Also, weight distribution for the actual configuration NASA would use varied significantly from the original requirement, increasing from 50 to 78 pounds. To accommodate NASA's needs and optimize our design, the configuration was changed to one of several shown in Appendix H.

T~ird, the method of attaching the forward and aft sections to each other was changed from the original angles and latching devices. Instead, a hasp latch was mounted to each torus and the two were hooked together using turn-buckles. This allows a limited degree of adjustment to ensure that the centerlines of the two halves line up.

The materials used were identical to those in the LDEFI. The end fittings were like the original design because less material was present with the IO-foot diameter for the inverted end. The changes in torus connection described for the LOEFI were also incorporated into this design.

Sizing of the tori was identical to that of the LOEFl, but minor problems were encountered which required removal of a five- to eight-inch section from the two larger tori.

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Expected but unusual changes in elongation resulted when sizing the main envelope. With conical sections to increase and reduce diameter, the biaxial stress was not uniform throughout the body, and each section acted independently. The large diameter section was 14 feet in diameter and about 14 feet from end to end of the conical sections (see Pigure 1 below). This meant the torus circumferences had to be corrected for proper skirt fit. Sizing in the fill direction remained the same, and elongation in the warp direction was compensated for by shortening the center cable slightly.

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Figure 1

The apparatus was constructed according to the drawings in Appendix I. One fabricating difficulty occurred while manufacturing the two large tori that was not encountered on the LDEFl. The tube diameter of these tori was large enough that two widths of material were required to form the tube. Thus, a butt seam now ran down the middle of the tucks, making heat sealing very difficult. To resolve this, the area had to be glued, activated and then heat sealed to provide sufficient adhesion.

2.0 OBJECT UTILIZATION

Appendix J, LOEFl An2 ~ Service Manual, contains information on assembly, inflation, servicing, maintenance, leak detection, repair and storage.

The articles were designed with gross ballast points located to compensate for the hardware weights as specified in the RFP or by NASA. These gross ballast points bring the objects into approximate balance about the three axes. Small lead weights should be placed in pockets located-on the tori to neutralize any remaining rotational forces. Weights should then be evenly distributed in these pockets to bring the inflatable to neutral buoyancy.

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APPENDIX A

LDEFI Proposal

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RAVEN INDUSTRIES, INC. PROPOSAL NO. ATDl182111

TECHNICAL SECTION

DESIGN AND FABRICATION OF

LONG DURATION EXPOSURE FACILITY INFLATABLE

Submitted to:

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National Aeronautics and Space Administration Lyndon B. Johnson Space Center

Houston, Texas

R.F.P. No. 9BB6-10-2-055P

15 November, 1982

Prepared By: Approved By:

'~~~ Q · L d..'1-J..,"'-1\/ -'" ~R. M.- Enderson j~ A. Winker

Sales Engineer Vice-President Applied Technology Div. Applied Technology D~v.

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1.1 INTRODUCTION

Raven Industrien, Inc. is pleased to submit this proposal in resp·onse ·to NASA's Request For Proposal No. 9~BI3G-lO-2-OSSP.

The proposed basic configuration is a cylinder with inverted and restrained ends. Tori are utilized at the ends to facilitate generating flat ends. The fifteen hard mounting points will be attached to the skin at the required locations. The proposed configuration will be capable of being made neutrally buoyant with and without all government furnished hardware attached.

The proposed material is a polyurethane coated polyester fabric. The polyester base fabric is selected for ~ts dimensional stability and the polyurethane coating for its abrasion resistance, helium retention and durability. The outer surface will incorporate an aluminized coating. The ~ominal material weight is 7.2 ounces per square yard.

Raven is a leading manufacturer of inflatables involving a wide range of materials. The proposed configuration will involve established and standard fabrication techniques. As a previous supplier of inflat.able. simulated payloads to NASA, Raven has a solid understanding of the requirement and is completely confident of our ability t~ meet the requirements for the LDEFI.

2.~ TECHNICAL DISCUSSION

2.1

The following detailed discussion of Raven's proposed design and fabrication objectives is presented with a plan for task accomplishment.

INFLATABLE CONFIGURATION

The proposed configuration of the LDEFI and associated sub-assemblies are shown in Figures 1 through 10.

2.1.1 MAIN ENVELOPE

The primary structure, shown in Figure 1, is a 13.7 ft. diameter cylinder with inverted and restrained ends with an over all length of 29 ft. A critical feature of the LDEFI is the limited volume for bouyancy to support required hardware. The inverted end design optim1zes available volume while continuing to provide sufficient skin tension for stiffness a~d hardware support.

Additionally, the inverted end configuration is more compatible than a hemispherical end in generating a flat

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end shape. The resulting torus radius at the end is only approxirn~tely 7 inches as shown on Figure 1.

The cylinder will be f~r~ed f~om l6ngitudin~1 gores with shaped ends to yield the inverted end shape. Th~ material at each end will be banded to a standard spool type balloon end filling. An adequate minimuM gore width will be maintained to provide the necessary strength. The fittings at either end will be connected with a steel rest:.aining cable. Details of the end fitting are shown on Figure 2.

-2.1.2 TORUS END SECTIONS

2.1.3

Flat ends are generated by using a torus with a 7 inch radius around each end of the cylinder (see Figure 1). Each torus will be constructed irjependently and attached to the cylinder.

'l'he skirts and end panels will be attached to the inflatable with hook and pile fastener (see Figure 3). The primary function of both sections is the generation of the desired shape and will carry no structural loads. Hard mounting points on the ends will be, as discussed in a following section, attached to "the main inflatable surface. These will be available through holes in the end panels. The ability to remove the end panels facilitates the location of inflation servicing hardware and will be a distinct advantage in case of leak checking or repairs.

DIMENSIONAL PARAMETERS

The following tabularized information lists the final dimensions and resulting surface area and "volume ~f_the LDEFI. The structure is subdivided as shown in Figure 4 for ease of understanding.

TORUS IEN_D~I ______ C_E_N_lT_E_.R __ C_Y_L_I_N_D_E_R _________ IE~NDI TORUS

FIGURE 4

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SURFACE GROSS SE~:I:ION LENG~H BnDIJJS lillE.A l[QlJJ.ME Ll.E.T

Centr;r 2 Ends 2 Tori Totals

2.2

Cylinder 277.75" 82.25" ·996.82 ft 3416.1 3 ft . 225.1 Ibs 41.125" 463.7 2 ft 794.0 3 ft 52.3 Ibs

--- 7.06" J,90.0 2 ft 8J s 6 3 ft SIS Ibs 17S0.5 2 ft 4293.7 3 ft 282.9 lbs

The tabulated lift is based on standard conditions (ISA) at sea level with a free lift of helium of .06589 pounds per cubic feet. The total gross lift would be reduced to 269.4 Ibs with an increased ambient temperature of 8~ F (helium free lift of .06275). This gross lift value will be used for all subsequent bouyancy calculations.

MATERIAL

The proposed material is a polyurethane coated polyester fabric.

The base fabric is a 220 denier polyester with a thread count of 52 x 52. The nominal weight is 3.2 ounces per square yard. The tensile strength is 198 Ibs x 215 Ibs, tongue tear strength is 15.2 Ibs. .

The total nominal weight of the coating will be 4.0 ounces per square yard. The coating will be distributed with 3.0 ounces per square yard on the inside surface and 1.0 ounce per square yard on the outer surface. ·The outer coating will be pigmented to give the appearance of aluminum.

The measured helium permeability of a similar material is less than one liter per square meter per 24 hours. The only difference in this material and that proposed for the LDEFI is that the base fabric weighs 4.2 ounces per square yard. The helium permeability of the proposed material, based on this comparison and Raven's extensive experience with coated fabrics, will also be less than one liter per square meter per 24 hours, well within the requirement of the statement of work.

A polyester base fabric is proposed because of its low elongation characteristics at low stress as compared to that of nylon. The polyurethane coating provides good abrasion resistance, helium retention and over all durability. The coating is compatible with both adhesive bonding and heat sealing techniques.

A sample of material representative of that proposed except for weight is enclosed.

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2.3 STIFFNESS

Three types of stiffness must be considered for the LDEFI; skin, bending, and torsional. The following paragraphs will discuss each.

2.3.1 SKIN STIFFNESS

FIGURE 5

3kin stiffness is a factor of skin stress in an inflatable. Longitudinal stress for a cylinder with hemispherical ends is given by:

SI = 6PR -r

In the proposed configuration with inver··.ed ends, the above relationship must be modified to the following:

SI = 6P(R2 -r 2)

2R

From Figure 1 R=82.25", r=41.l25 and for an operating pressure of 3 inches of water:

SI= LIaS) (82.25 2 - ·.i1.125 2)

2(82.25)

&:: 3.33 lbslin

Lateral skin stress is represented by the following equation:

52= 6PR

For an operating pressure of 3 inches of water and radius of 82.25 inches:

52 = (.108 lb/in 2 ) (82.25 in) &:: 8.88 lbs/in

8

ORIGINAL PAGE is OF POOR QUAUT'r

The skin stress tangential to the end plane of the inverted ends of the main envelope will be governed by the following equations:

ORIGINAL PAGE (S OF POOR QUALITY

FIGURE 6

Again, for three inches of water pressure:

SI= .108(41.125) a 4.44 Ibs/in

S2= .108(41.125)/2 = 2.22 Ibs/in

The end tori will be inflated to the same operating pressure as the main envelope. To determine the maximum skin stresses in each direction, the following equations apply:

Sl = t1Pr' (2R-3r') 2R - 4rl

S2 ='t1Pr' -2-

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SI

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Where R = 8?25 and r' = 7.06;

SI = .108(7.06) (164.5-21.18) (164.1)-28.24)

= .80 Ibs/in

2.3.2 BENDING STIFFNESS

S2 = .108 (i.06) 2

= .38 1bs/in

Bending stress is related dir~ct1y to longitudinal stress for a cylinder. Ths first wrinkle in the skin of the cylinder will occur l-lhen bending stress equals longitudinal stress. For the proposed configuration, this can be represented as follows:

M = S 1I'R2

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For the stress determined in 2.1.4.1 of 3.33 Ibs/in for the 82.25 inch radius:

Ma (3.331bs/in) X'II'X (82.25 inches)2 • 70,773 in 1bs . a S090 ft lbs force

Increasing internal pressure yielding higher longitudinal skin stress will increase the bending force required to cause wrinkling.

2.3.3 TORSIONAL STIFFNESS

Thin, flexible fabrics vary wide in their reaction to shear in the plane of the material with thread denier, weave and coating material. Torsional loading also causes a reduction in lateral stress in the material and thus ~educes skin tension. As the fabric is displaced in ':orsion and lateral stress is reduced, the material ~ecomes susceptable to flexural displacement where lateral loads rapidly diminish.

Torsional stiffness of a rigid cylinder is proportional to the shear modulus of the material and is usually represented by the following equation:

Torsional Stiffness M = 1T(O"-d")G ....! 32L a

Where Q = angular displacement, M = torsional moment applied, G = shear modulus, 0 = outer diameter, d = inner diameter, L = length.

RFP OSSP requires a torsional stiffness of:

~~ = 3000 ft lb/radian

e-Assuming a material thickness of 10 mils and shear modulus G = 3000 PSI*

lvI.r = 'II'[(l64.5)"-(l64.48)1t]3,OOO = [(in)"-(in)"]lb/in2 =in/lbs _ 32 (360) (in) rad o

= 291,290 in Ibs/RAO = 24,274 ft lbs/RAO

*The shear modulus of 3000 PSI was derived from test data determined from mocel testing of pressurized cylinders. under torsion constructed of coated fabric (NASA TN D-755 Aug 61). This material is somewhat heavier' than the proposed LDEFI material but .should yield a shear modulus on the same order of magnitude.

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The shear modulus required by the statement of work would be 30.9 PSI. Synthetic rubber has a shear moduluo of 5-20 PSI and when combined with a fabric, this modulus increases by two orders of magnituoe or more.

The actual value for torsional stiffness of the LDEFI structure would fall well above the reauirement set in the statement.of work, but precise determi~ation would only be possible through the collection of empirical data.

BOUYANCY

The bouyancy of the LDEFI as determined in section 2.1.3 is a gross lift of 269.4 lbs. A gross loading computation must first be made to place the center of gravity at the volumetric center of the LDEFI. The following table shows 17 required hardware mounts, their respective weights, and their x, y, and z locations (see Figure 8) with respect to the volumetric center. Points 1-15 are the required 15 nard points. Point 16 is the main inflation port and point 17 is the gross ballast point. The summation of moments in each axis is equal to zero.

POINT WT X Y Z X Y Z m m m 1 18 .. 15 22.3 41.125 71.23 406.975 750.53 1299.95 2 18.25 22.3 71.23 -41.125 406.975 1299.95 -750.53 3 8.25 5.0 14.0 81.05 41.25 115.5 668.66 4' 8.25 176.0 14.0 81.05 1452.0 115.5 668.66 5 8.25 5.0 14.0 -81.05 41.25 115.5 -668.66 6 8.25 176.0 14.0 -81.05 1452.0 115.5 -668.66 7 8.25 - 5.0 -82.25 0 41.25 - 678.56 0 8 8.25 -180.0 37.2 -20.2 -1485.0 306.9 -166.65 9 8.25 -180.0 37.2 20.2 -1485.0 306.9 166.65

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167.15 0 0 0

Cable and Spools 6.5 1bs Total Hardware Wt. 167.15 Ibs Trim Weights 10.00 1bs

ORIGINAL PAGE (S Fabric Weight 85.25 Ibs 269.4 1bs OF POOR QUALITY

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2.5 FABRICATION AND CONSTRUCTION

The techniques which will be uied to ~abricate and " construct the LOEFI arc well proven and reliable. Quality

control is built into each step of the proc'ess, i.e.; random samples of the materials will be tested to ensure the material meets desired specifications, seam samples will be t~sted for strength.

2.5.1 MAIN CYLINDER CONSTRUCTION

The main cylinder will be constructed"of twelve gores. The end of each gore will split to form two gores for a more uniform construction of the inverted end (see engineering drawing C-51510). The seams will be bonded using high strength adhesives final assembly and checkout will be accomplished for the LOEFl with helium.

2.5.2 'rORUS CONSTRUCTION

Several methods exist for the fabrication and construction of a torus. With the large difference between the outside torus radius 81.5 ±. .75 inches and the tubular torus radius 7.0 ±. .06 inches, the torus may be formed of gores, tucked tuLu1ar, or a modified gore tubular method. The latitude provided by these options allows for the l3~lection of the design \·ihich would afford best distribution of skin stresses with other considerations of porosity, esthetics, maintainability and repairability.

2.6 ATTACHMENTS

Along with the fifte~n required hard point attachments, several other types of attachments are required. Each will be discussed in the following sections.

2.6.1 HARD POINT ATTACHMENTS

The fifteen hardware attachment mounting points will be mounted on the skin of the LOEFI in the manner shown in Figure 9. The mounting ring w ill be ccnstructed of 1/2 n

60-64 aluminum with a matting inside ring constructed of 1/4n aluminum. Gaskets will be placed between each ring and the fabric which will be reinforced in the area of the interface.

2.6.2 BALLAST AND TRIM WEIGHTS

Ballast and trim weights will be contained in four pockets at each end of the LDEFI construction.

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2.6.4

The LDEFI will consist of three distinct air chambers. The two tori will require only a r.ingle Schrader "valve for both filling and top off due to the relatively low volume of helium contained in each. A second Schrader valve will be installed in each air chamber to allow pressure monitorin~ during servicing.

The main cylinder will have a rapid fill inflation tube (sho\Oln in Figure 10) which will be used for initial servicing. The inflatable will be taken up to just prior to skin stretch using this inflation "port. The cover pla~e will then be installed and either of two Schrader valves located in the ends of the LDEFI main envelope will be used to reach operating pressure.

The rapid inflation port will be located as shown on !:'igure a so as to reduce the total amount of weight ~equired to reach the coarse balance of the LDEFI.

'l'IE Dm~N LINES

Tie down lines will be attached to each end of the main envelope on a "D" ring at the crossing point of three load webbings which will be adhered to the inverted end. The nD n ring will protrude through the end panel.

2.7 SAFETY

Safety is paramount in the design of any pressurized structure. Even with the low operating pressures of the LDEFI, an examination of the most serious failure must be made. "

The restraining cable and end fittings have been determined as representing the greatest safety hazard if a failure were to occur. The restraining cable supporting the inverted ends will be constructed of steel aircraft cable. The tension is governed by the follow ing relationship:

For a working pressure of 3 inches of water pressure and a radius of 41.125 inches: a

t= .loa (n) (41.125) 2

= 574 lbs

Usin~ a safety factor of 10, 7/32 inch 7x19 aircraft cable will be used. A proportionalli larger cable will be used if it is determined that higher operating pressures are required.

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2.8 MAINTENANCE

Maintenance and servlclng are minimal as the LDEFI will only require helium servicing periodically. It is recommended that prior to beginning an operational day the internal pressure be checked and brought up to working pressure. This will insure a minimum of 8 hours service free ope~ation.

Tears, holes or leaks must be repaired with adhesive patches. A detailed discussion of this procedure will bc accompanying the LDEFI with a field repair kit.

3 • 0 MANAGEl-lENT

3.1 GENERAL

The proposed program '~ill be conducted within the Applied Technology Division of Raven Industries. Mr. James A. Winker is a Vice-President of Raven Industries and manager of the Applied Technology Division.

3 .2 PROGRAM MANAGEl-1ENT

The primary program management will be assigned to the .engineering group. Hr. Patrick J. Cannon is the Engineering Group Manager. The program will be conducted on a project basis with an assigned project engineer from within the engineering group. Assignment of the project engineer will be made at the time of contract award and would be dependent upon existing requirements at that time. The engineering group will have the total technical responsibility as well as data management, documentation and conference requirement~

Fabrication will be coordinated with Mr. K. L. Tekrony, Production Manager for the Applied Technology Division.

3.3 PROGRAM SCHEDULE/PLAN

A program schedule outlining the major tasks with manpower loading is enclosed as Figure 11.

17

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P,ROGRAi1 PLAN TASKS MlD f'1Ai~PO\'lER LOADli~G

MI~~';T;~E'~;~;ON;HS I-,:-r--l----rJ 01 I" '-1--'-f1-J 1----1 FROM ~?-_~IEAD 1 I~ 4.. 5 ~7_L~~_ 10 :_1 12

:::::: D ;:::FACE MTN' G. IjJJ +Jjf-I-ITlJWj=r-:~...-J-l.--I ___ .. __ .. __ E._.NI.T-XQN gi-~,~jddd-;l~ -~=I=1 I I 1

HATERIAL PROCUREMENT . . .- --- _ .. _______ ----.. -----------------1

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DETAILED DESIGN ~ - - --

_~~~~hii9~---- -- == ==l==~~~ H-j I; L jj=1:Jj-O ~~ .- :~~~~;i~~~ _CH~CKOQ~--~ . ~ =- =- =-1_ = ~l J~~~':~- :-1- - -~ ~tt~= t ! ~ _~-~~-~~;~-?~~§~:gNT . ---'--1---------'-- --'--' ___ . __ ._I ____ .l.~ ___ ---==-~ -- -- --- __ J_I_I_'-__ ~~ ----- -' -J --. -- -. -- -- -- -- - -I~r - --- -- -- -J~_L I.~ ~ iii ~:_:==~= _~~==-_~~~~~:' =-_:-l-_J~T ~-_~=~_~t:C~~L--___ -= ~~- --- jj~---f-__ ~ --ABOR CATAGORIES & HOURS ~ ._--._._----------- .. _------------ -- ---- -_ ... -_. __ . -- --- -- - -- -'-. --ENGINEER_______ _ _____ 6..1. ____ §.~.:.. _6_.1 __ 3.L --24 _~6 120 . . 504

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__ ~~E~l_~~Y --- ---- . ---1-- ------ 2 0 r~~~ -: ---- ----24-0"'----._~J_t!.oCHINE_SHOP_. ________ ' ______ ~ ______ . ____ 40 _~ ___ ___ __ _ ___ 80_~ __

- !-t~NX~-~Y.;~~~~S __ · _=--::..-:--) -104 iS4224 2~~}o4 -ill _ 12;;-j== -- 132-4---

FIGURE 11 ~

PROPOSAL CLARIfICATION

ORIGrNAL PAGE '9· OF POOR QUALITY

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1. 0 SKIH'l'S AIm Elm PAlmLS

Quontion being ~ddrecncd: Calculate and ntate nurface area and material of the zkirts and end panelc.

The end panels and nkirts will be constructed of a 2.16 ounce c1acron poll'ester baf.ie fabric ,.,rlth either a .5 ounce pigmentC'd po1yur<:thane conting or n .5 mil aluminized mylar laminate: on the outer surfnce. The end pnnels ,.Jill b( circular in shc'Fe ''lith a cli,llteter of 152.5". The skirt \olill fit circumfe:rentially around the main envelope and end toruf.i. The flat panel ,-Jill have approximnte dirnenf.iion~ of 516.8" x 36". The total surfnce area of the skirts (129.2 ft 2 each) and end pnnels 026.0 ft 2 each) is 512 ft.2or 56.9 yds?

2.0 GROSS BALLAST POINT

Question being addressed: point?"

What is meant by ngross ballast

The gross ballast point is the position (point 17 on Figure 8 of Ref. B) at which the absolute minimum amount of ballast

,.can be pl~~cd to bring the center of mass concentric with the volu~etric center of the LDEFI. This point is not intended to be used to reach neutral buoyancy. Only to balance (;ut rotational moments about e.:lch axis. Some fine trimming \-lith Yleight5 ~n the end pocket~ tlay be required to nfine tune" the rotational moments. A tubular 1.25" diameter webbing filled with lead shot in one foot s~ctions will be used to cOlilprise the "!eightz for the. oss bnllast as Hell as trim "le ig ht s. Each one foot sect ion \01 i 11 ,~e ig h approxiffiately 3.25 lbs. and will require seven such bags for gross ballast.

An area of reinforced material will be located about the gross ballast point to which the weights will be at~ached oy means of clastic straps (sec Figure 1). The sk1rt will cover the mounting area of the gross ballast point and is easily removable by means of the hook and pile fastener. Thin '-lill alloH some or all of -the ueight~ to be removed to compensate for nny government provided equipment which may be removed and maint.:lin rotational balance.

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3.0 TRIM POCKETS

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ORIGINAL PAO­OF POOR Q ';': IS .. UALITY

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FIGURE 1 . '

Queztion being addressed: _ Specify the location and orientation of weight pockets and total weight each can

" hold.

. Once the LDErI has been brought into gross balance by means of the gross ballast point, trin weights nay no\., be placed in eight locations as necessary to trim out imbal~nces ar.d bring the LDEFI to nelltral bouyancy. On each end, there w ill be fou r lcca ticn::; on the main envelope which \oleights may be attached as described in 2.0 and Figure 1. This will facilitate balancing out any l£rge amount of buoyant force which must be overcome to reach neutral. Adjacent to each of these locations \01 ill be a pocket located on the end panel and will proviuc a secure locaticn for small amount of trim weights. The pocket \-rill be closed by a strip of hook and pile fastener on the open cnd flap.

Each inner location on the main envelope ends will be designed to acco~odate 25 lbs. of Weight while the trim pocl:ets \Olill hold up to 5 Ibs. 'I'his will enable the LDEFI to ~c brought to equilibrium with all government equipment removed and a best lift condition of 282.9 Ibs.

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OHi-::i~~i~L P:·\U::: ;~ OF POOR Q~;~Li·I ... t

Oue~tion bein~ addrenced: lu the tDRr! capahle of being neutrnll y buoYLlnt (1:1 dcsc r iued in thc prop0::'ill? Sho\'I calculation:. to that Cl fect.

\\'~ile (1ns\lerin~ the C:lforc::;l:ntcd questions, it \H'l.S rcalized t h (I t the \-/ e j ~ h t 0 f t h (: end pan c 1 san d ::;~: i r t !> \-1 ere 1 eft 0 f; f: of. the buoy<:ncy calcul<ltionr:. To compensate, <l slightly ligllter \'lciyht ·materii.ll is being proposed for use in the LIJI:l·'! •

The base material remains a dacron polyc~ter fubric of 70 denier thrNHl and a thread count of 107 x 105. 'l'he nominnl \'1eight or the fabric is 2.2 ounces per square yard \'lith tensil strengths of 111 x 110.5 1bs. and trapezoidal tenr strength or 20 1bs. This yields a minimum safety factor of 12.5.

The fabric \·:ill be coated on the inside \-lith 2.5 ounces per squDIe yeard of polyurethane. The outside will either be cOilted witl, a pigrnentecJ urethane to produce a polished aluminum ".pi";car<lncc (~'cc material r.amplc: in Ref. m or a .5 mil layer of alu~inized mylnr will ~c laminated to the surface prooucing a highly polished appearance. The final nonlinal fubric \leight is 5.2 ounces per square yard. Finnl male rial se lec t i on \/111 bc madc du r lng prcl iminilry des ign rev iC\-ls wi th W\Sl,.

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ORIGINAL P/~G~ IS OF POOR QUALITY

Encloccd is ~ stre~~-~tr~in curve of the material ~hovfng ~ linc~r elongntion rute \'Ih10h would renult: in ~ 1.25~ elongntjon Dl ~ mnxirnum opar;::ting lc~d or 0.0 Ib~./in. This graph al~:o uho\1s a Cjr'-lb ten~il ntrclIgl:h of 235 Ibr::./ in.

'.rho fo)10\linq is it t'-lbul~tion of blloy~ncy bu~ed on \'/orst case lift of 269.1. Ibs. an \-Iould be generutcd at 05 F Chcliulil free lift:. of .06275):

Cable ~nd ~rools Gove:rJlli'.enl". 'lIi1rcl\!i::re Hounting lIard;nlre/Gro~5 nal1~st Trim Neighl:s

*Main Fabric + 10\ **Skirts bnd End Panels

Total Gross Life

6.5 1bs. 125.0 lbs.

42.15 Ibs.· 14.04 1bs. 69.53 Ibs.

...J.L..3JL1b:J • 269.1; l1.>s.

*194.5 squ~rc yards Q 5.2 oz./yd! plUG 10' ** 56.9 square yarus g 3.2 oz./yd~

5.0 LIFl::TIHE

Question being uc1(:rc~sed: l'That is the service life of the LDEFI?

The nervice life of the 5.2 cunce coated fabric used to construct the main envelope and end tori is a minimum of 5 years. All other cocponents have a virtually limitless life expectancy if maintained within the design criteria. The actual life of the LDEFI ,-:111 be determined by the degree of

I. use, stress, and abuse which it undergoes. No means of estimating these effects on the lifetime exists.

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I" APPEnDIX B

I RBADS 1161

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Prepared by:

H. 'L. ~7est Project Engineer

COATED FABRIC, NASA INFLATABLES

Applied Technology Division

RBADS 1161

Applied Technology Division

Raven Industries, Inc. P. O. Box 1007

Sioux Falls, SD 57117

I('IAI VI Eli'll industries, inc.

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COATED FABRIC, NASA INFLATABLES

SPECIFICATION NO. RBADS 1161 D~TE ISSUED: 15 July 1983 Page 2 of 2

1.0 Base Fabric

Il"{ I t\ I v I C.II 'J I industries, inc.

The base fabric shall be a Dacron polyester made 0t 70 denier yarns having a base weight of approximately 2.0 oz/yd •

I 2. 0 ~Qating I-

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Side one shall be a heat and solvent sealable polyurethane which will constitute a helium barrier with permeability rates as established in pa~agraph 5.3 of this specification. Side two shall h2ve a base coating or adhesive with approximately .5 oz/yd of a bright aluminized polyurethane.

3.0 COD?tructipn

The construction shall ~e as specified above with a total weight not to exceed 5.0 oz/yd •

4.0 Width

The minimum trimmed width shall be 43 inches.

5.0 Physical Properties

The finished fabric must meet the minimum values of the following listed physical properties.

5.1 Tensile Strength (one-inch strip method)

Machine direction - 50 lbs. Transverse direction - 50 lbs.

5.2 Tear Strength (tongue tear)

(minimum) (minimum)

Machine direction - 1.5 lbs. (minimum) Transverse direction - 1.5 lbs. (minimum)

5.3 Permeability (helium)

Maximum acceptable - 1 liter/meter2/24 hours

5.4 Seam Strength

The peel strength of a one-inch heat sealed lap seam (side one to side one) shall be a minimum of 7 lbs. The peel strength of a one-inch heat sealed lap seam (side two to side two) shall be a minimum of 4 lbs. This test shall be accomplished on a sample prepared using the hot wheel sealing method.

5.5 Acceptance Tests

Failure of the fabric to meet the listed physical propertie_s __ !Ilay ~o)~~_~i~ute ground for rejection.

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Raven Report No. R0184-002

APPENDIX C

Material Test Results

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APPENDIX D

LDEFI Drawing Package

i' NOTE:' Because of its bulk, this drawing package is included I as a separate package with this report.

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APPENDIX E

Torus Construction

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Raven Report No. ROl84-002

TORUS CONSTRUCTION

LDEPl and STTA

j. 1.0 BASIC DESIGN

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The tori were constructed using 36 gores to provide a smooth, non-lobed shape. Because the silver side of the material was difficult to seal, a butt seam would have been required with the sealing strip for each gore pattern. This would have produced three times the number of seams in the material compared to using only the radial seam. To prevent this, tu~ks were made in the material in the same gore shape as would have been cut.

1 2.0 PABRICATION

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The torus lay-flat was marked with the 36 gore patterns, and glue was placed on the silver side of the material. After allowing the glue to dry, a hot iron was used to tack the tuck in place. The tuck was then run through a heat sealer to fuse the three layers of material. Several passes were required, depending on the width of the tuck.

The ends ·of the tucks tended to pull loose due to a concentration of stress. To eliminate this problem, a 1 x 2 inch patch was sealed over this point on the white side. This reinforcement removed any tendency to separate.

The two ends of the lay-flat were sealed together with a butt seam. A radial butt seam formed the tubular shape.

3.0 CONSTRUCTION DIFFICULTIES

The only major difficulties which occurred were in construction of the tw~ large tori fo~ the STTA. Two pieces of material were required to form the lay-flat. The material was sealed together with a glued butt seam to prevent heat shrinkage. The tuck now included six thicknesses of material, and heat would not adequately penetrate all layers. This problem was alleviated first by activating the glue with solvent and then running the material through the heat sealer. Test samples using this procedure produced extremely strong seals.

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Raven Report No. R0184-002

APPENDIX F

STTA Proposal

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RAVEn INDUS'l'RIES, Inc. PROPOSAL 1m. ATD0882092

TECHNICAL SECTION

DESIGN AND FABRICATION OF

SPACE TELESCOPE TRAINING ARTICLE

Submitted to:

National Aeronautics and Space Administration Lyndon B. Johnson Space Center .

Houston, Texas

R.F.P. No. 9-BC72-93-2-66P

Prepared By:

~~~~'-~ R. M. Enderson Sales Engineer App~icd Technology Div.

6 August, 1982

ice President Applied Technology Div.

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2.1.1

INTRODUCTION

Raven is pleased to submit this proposal in response to NASA's Request For Proposal No. 9-DC72-93-2-66P.

Raven's proposed basic configuration for meeting the requirements of the Space Telescope Training Article (STTA) is a 10 ft. diameter cylinder with inverted and restrained ends. Tori are used to generate flat ends on the 10 ft. diameter sections. Tori and/cr a rigid structural ring are proposed for generating the 14 ft • diameter sectio~ of the AFT article.

Two different materials are being considered. One is a lamination of polyester film and polyester fabric. The other is a urethane coated polyester fabric. The polyester fabric is, the same in both configurations.

The requirement presents an interesting challenge. Raven is completely confident, though, of its ability to successfully accomplish the requirements of the statement of work. Developed fabrication t~chniques will be utilized regardless of the material confi~ura­tion selected •

A detailed discussion of Raven's proposed configuration is presented in the following sections as well as a plan for accomplishing the task.

PROPOSED DESIGN

STRUCTURAL CONFIGURATION

The proposed configurations for the Forward and Aft sections of the STTA are shown on figures 1 and 2.

FORWARD SECTION

The basic structure, as shown on figure 1, is a 10 ft. diameter cvlinder with inverted and restrained end sections. The inverted end configuration was selected primarily because this shape is more compatible than he~ispherical ends in constructing flat ends.

The cylinder will be formed irom longitudinal gores with shaped ends to yield the inverted end shape. The mater ial at each end w ill be banded to a standard spool type balloon end fitting., An adequate minimum gore width will be maintained to provide the necessary

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strength. The fittings at ~ither end will be connected with a steel restraining cable. Details of the end fitting are shown on figure 3.

The structure incorporates two tori which fac~litate "affecting flat ends and connecting the two sections together. This second factor will be discussed in detail in a following paragraph.

The exterior surface is completed with the two skirt sections and circular panels at either end.

The cylinder and two tori will be fabricated as Deparate items and then joined together with the skirts and end panels. Adhesive bonding techniques will be used in the fabrication. It is not determined at this t.ime if the skirts will. employ a laced section to establish skin tension or if this will be dependent upon stress developed by inflation.

Critical parameters of the Forward section as proposed are as follows:

*Inflatcd Volume

*Gross Lift

*Total Surface Area

1633 Ft. 3

107 Lb.

140 Yd. 2

~hese parameters will be referenced and considered in the discussion on buoyancy.

AFT SECTION

The proposed configuration is shown on figure 2. " - "

The basic structure is the 10 ft. diameter cylinderical section as used in the Forward section. The 14 ft. diameter section will be formed by either two tori or one torus and a structural ring~ The configuration of the end if the structural riug is used will be essentially the same as the ends of the simulated payloads previously supplie~ to NASA by Raven.

Fabrication and assembly of the Aft section will be Similar to that of the Forward section.

Critical parameters of the Aft section are as follows:

*Inflated Volume

*Gross Lift

*Total surface Area

2

3000 Ft.3

197 Lb.

260 Yd. 2

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The surface area is based on using two tori in configuring the 14 ft. diameter cection. The volume between the 10 ft. and 14 ft. diameter surfaces will be only slightly pressuriz~d.

. STIFFNESS

The basic stiffness of a pressurized cylindrical shape is directly related to the longitudinal stress in the material. In a·cylinder with hemispherical ends the longitudinal stress is given by:

S ... fl PR 2

In the proposed conflguration ,with inverted ends the above relationship has to be modified to the following:

S ... fl P (R2 - (2) 2R

Rand r are as shown on figure 1 and the values are 5 ft. and 2.5 ft. respectively.

The stress in a 10 ft. diameter cylinder with hemispherical ends and pressurized to 3 inches of water pressure is computed to be 3.25 lb./in. , The longitudinal stress with the ends inverted is computed, at the same pressure, to be 2.43 lb.lin. To generate a skin stress of 3.25 lb.l in., the proposed configuration will have to be pressurized to 4.0 inches of water pressure.

The stress in the restraining cable is given by the following relationship:

S· ; flp n r2

At 4.0 inches of water pressure this stress is computed to be 408 lb.

The first wrinkle will occur in a cylinder when the bending stress equals the longitudinal stress. For the proposed configuration this can be represented as follo\~s:

M ... 12 S n R2

With a skin stress of 3.25 lb./in., M computes to be 3063 ft.llb.

The basic stiffn2ss of the STTA will be related to the minimum or 10 ft. diameter. If a maximum bending

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stress of 30G3 ft.llb. 1s not adequate a higher degree of pressu r iza tion w ill have to be considered. The Computed material stresses are nominal and a higher

. degree ·of pressurization can be easily tOlerated. The tori will be inflated to a pressure that will yield' a skin stress equivalent to that of the cylinders.

The other factor that will directly effect the stiffness of the assembled STTA is the configuration of the interface connection. Raven's proposed method involves attaching rigid supports to the mating tori of the Aft and Forward sections and utilizing latching clamps to secure the connection. A sketch of a typical connection point is shown of figure 4.

The interface connection will impact directly also on the logitu~inal alignment. A misalignment of one degree on the interface plane will cause an offset of approximately 4 inches at the end of the STTA. The rigid supports will provide a means of shimming as necessary to obtain proper alignment. The latches will be installed after correct permanent shimming has been accomplished. This task of final assembly and checkout will be done with the STTA inflated with helium.

The number of connection locations and the material for the rigid supports is to be determined. There is a signif icant degree o!: la ti tude in conf igur ing the supports as well as available latch mechanisms. The latch protrusions will be limited to less than one inch from the surface of the STTA units.

ATTACHMENT HARDt-1ARE

2.1.4.1. HARD MOUNTING POINTS

The proposed method for attaching the hard mounting points vary depending upon location and are discussed accordingly.

a. Aft Section - Station 3.0

Rigid supports similar to the interface supports are proposed to be used since the radius of the torus tube is approximately six inches and the center of the hard mounting is only three inches from the end of the inflatable. The hard pOint will be bolted to the rigid support stations. See figure 5.

b: Aft Section - Stations 28.0, 41.0, and 121.0 Forward Section - Station 81.75 Aft Section - 14 ft. Diameter End

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At these locationn the hard mounting points will be bolted to a cl~mp ring located on the inside surface, sec figure 5. The surface at station 121.0 of Aft section is not a pressurized surface as such. Additional support at this stations, normal to the surface in direction, may have to

,be obtained with an auxiliary support attached to the pressurized 10 ft. diameter surface.

2.1.4.2. VELCRO PILE

The velcro pile patches will simply be adhesively bonded to the surface at the required locations. Rigid supports will again be utilized at station 6.00 of the Forward section and the end of the Aft section if the locations cannot be located on the curved surface of the tori.

2.1.5. MISCELLANEOUS ATTACHMENTS

2.1.5.1. BALLAST AND TRIH

A sui table number of pockets .and weights will be 'f'rovided to effect neutral and balanced buoyancy with or without the government furnished hardware attached.

2.1.5.'2. TIE D01'1N LINES

2.1.6.

2.1.7.

A fitting will be provided at the geometric center of both ends of both sections to which a tie do\'ln line can be attached.

INFLATION SYSTEM

Inflation ports will be provided in accordance with the statement of work. Two Shrader type valves will be provided at each end of a unit. This will provide' a means of ntopping offn the inflatable while monitoring pressure. Separate inflation means will be provided for inflating the tori. The large bore filling port for the cylindrical sections will be similar to those provided on previous SSSP's supplies by Raven.

FABRICATION & CONSTRUCTION

Adhesive bonding techniques will be utilized in fabricating the inflatable articles.

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The tori will be fnbricated from tubular elements. Ench tori will conniut of 24 elements. The e.ements are connected with a circumferential seam. The procedure is standard nnd used succesnfu11y numeroun times in making yas tight structures. •

The cylinders will be fabricated from straight longitudinal gores with shaped ends to form the inverted ends. Eighteen gores will be sued for ~ach cylinder. The proposed procedures are, again, standard.

Final assembly and checkout will be accomplished with the STTA inflated with helium.

2.2 BUOYhNCY

In analyzing the buotancy of the STTA an estimate of material weight has to be made. This estimated material weight is initially selected as 4.0 oz. per square yard. The weight and buoyancy of each section of the STTA and the assembled system is estimated as follOWS:

Fot\ozard Sect ion

1. Volume - 1633 Ft. 3 2. Gross Lift - 107 Lb. 3. Weight

a) Two hard mounting polnts at 1.5 lb. each

b) Attached government hardware

c) Fitting and misce1~aneous d) Material - l402Yd.

at 4.0 oz./yd. ..­(includes 10% overage allowance)

Total Weight 4. Net buoyancy (107-65)

Aft Section

1. Volume - 3000 Ft. 3 2. Gross Lift - 197 Lb.

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3.0 Lb.

12.0 LB.

15.0 LB. 35.0 Lb.

65.0 LB. 42.0 LB.

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at 1.5 lb. each b) Attached government .38.0 Lb.

hardware c) Fittings and misce~laneous 25.0 Lb.· d) Material - ~60 Yd. 65.0 Lb.

4.0 oz./yd. (includes 10% overage allowance)

Total l~eight 155.0 Lb. 4. Net Buoyancy (197-155) 42.0 Lb.

Obtaining balanced and neutral buoyancy, with the net buoyancy available for ttim weights, will not be a problem for either the assembled or the individual sections. The existing net buoyancy will also ,llow consid~ration of alternate materials. Using a 5.2 oz./yd. would increase the \'1eight of the Forward section approximately 10 lb., the Aft section 20 lb.· Sufficient buoyancy would remain for trimming.

The Aft section buoyancy and \-leight is based on using a torus to obtain a flat end on the 14 ft. diameter. This torus would weigh approximately 8 lb. The buoyancy is adequate if this torus is eliminated to consider the alternate configuration of using a structural ring to ob~ain a flat end as shown on figure 2.

MATERIAL

Two different material configurations, a lamination and a coated fabriC, will be considered for fabricating the STTA. A description of each is as follows:

Lamination

This proposed material is a lamination of polyester film and a type 68 dacron polyester fabric. The film on the outer surface would be·a 0.5 mil aluminized polyester film. The inner surface would be a 0.75 mil clear polyester film. The Ultimate tensile strength is approximatel! 110 lb./in. The maximum weight will be 4.0 oz./yd.. A computed factor of safety at a pressure of 4.0 inches of water is 12.7.

Coated Fabric

This proposed material would consist of the same ~ase fabric as used in th~ lamination. The fabric would be coated with 3 oz./yd. of polyurethane. The coating on the outer surface would have a polished aluminum

7

appearance. The strength would, with the same base fabric being used, be the same as the lam1fation. Total \-Ieight would be approximately 5.2 oz./yd ••

Either of the proposed material configurations will· meet all of the requirements of the statement of work. There are advuntages and disadvantages to be considered with both with respect to ease of fabrica~ion. Functionally they will be very similar. 1\ Kevlar base fabric was considered but discounted on the basis of reported field experience.

Samples of similar material configurations are enclosed as figures 6 and 7.

The decision on the material will be made at the time of the preliminary design review. NASA's preference will be a factor in the decision.'

3.0 Ml\NAGEHENT

3.1 GENERAL

The proposed program will be conducted within the 1\pplied Technology Division of, Raven Industries. Hr. James A. Winker is a Vice-President of Raven Industries and manager of the Applied Technology Division. The latest annual report of Raven Industries is enclosed with this proposal.

3.2 PROGRAM MANAGEHENT

The primary program management will be 'assigned to the engineering group. Hr. Patrick J. Cannon is the Engineering Group Manager. The program will be conducted on a project basis with an assigned project engineer from within the engineering group. Assignment of the project engineer will be made at the time of contract award and would be dependent upon existing requirements at that time. The engineering group will have the total technical responsibility as well as data management, documentation and conference requirements.

Fabrication will'be coordinated with Mr. K. L. Tekrony, Production Hanager for the Applied Technology Division.

Resumes of key personnel that may be assigned to the program are enclosed in Appendix A.

8

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3.3

3.3.2.

3.3.3.

3.3.,J.

3.3.5.

l?ROGR1\I1 SCIIEDULE/I'L1\N

1\ progrnm schedule outlining the major tasks to be accompliohed is enclosed as figure'S. A discussion of -the tasks is preoented in the follo\dng paragraphs of this section.

INITIAL X~TERFACE MEETING

A primary objective of this meeting will be to critique Raven's proposed configuration with respect to the requirements of the statement of work and resolve any deficiencies or questions in the proposed program andlor interpretations of the statement of work. This meeting is proposed to be held at Raven'~ facility in' B;'!)ux Falls.

SYSTJM PEFINITION

~he proposed configuration will be modified in accordance with the determinations of the initial interface meeting- Petail design of components will be initiated.

l?REJ.,IMIN1\lW DESIGN REVIEW

~he syatcm as defined and design accomplished under task 3.3.2. will be reviewed,. 1. major objective will be to finalize the material configuration.

MATERIALS PROCUREf1ENT

~he proposed polyester base fabric' is a long lead time item. It is proposed that this material br ordered upon receipt of contract since it will be used regardless of the final material configuration. The decision as to whether the fabric will be coated or laminated will be made at the 'time of the prelimina.ry del3ign review.

DETAILED DESIGN AND TESTING

~he detailed design will be completed under this task. ~ests will be accomplished as necessary to veriZy del3;'gned configurations are functiona~.

9

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3.3.G. CRITICAL DESIGN REVIEW . .

The final detailed design und results of tests will be presented as well as the status of. purchased material.

3.3.7.' DESIGN MODIFICATION

3.3.8.

3.3.9.

3.3.10.

3.3.11.

3.3.12.

4.0

Any design modifications that may result from 3.3.6. will be accomplished.

FABRICATION

FINAL ASSEl1BLY AND CHECKOUT

DELIVERY

INSTALL1\TION

SUBIUT FINAL REPORT & PROGRAM END

BACKGROUND

The Applied Technology Division of.Raven is a major designer and fabricator of inflatables. The products range from polyethylene zero pressure balloons to heavy lift balloons utilized in the logging industry • .. More different configurations of materials are utilized by Raven than probably any other one ·single balloon manufacturer. The materials range from 0.5 mil polyester films to 2coated fabrics weighing approximately 16 oz./yd ••

Raven is very familar with the requirements of NASA for simulated payloads. Raven has previously worked with NASA in the design and fabrication of two previous simulated payloads. We are confident of our proposed approach to this requirement.

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URETHANE COATED POLYESTER FABRIC

FIGURE 7

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:'IILESTO~ES /MONTHS FROM GO-AHEAD

I , TASKS

~l. INITIAL INTERFACE MTN'G.

L 2. SYSTEM DEFINITION

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Raven Report No. R0184-002

APPENDIX G

STTA Alternate Sizing Analysis

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THE MOMENTS IN THE X AXIS EQUAL-800.432 THE MOHENTS IN THE Y AXIS EQUAL 91 THE l>lOHENTS IN THE Z AXIS EQUAL 0

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POINT 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

THE HOHENTS THE HOI·1ENTS THE MOl·IENTS

ORIGINAL AFT SECTION

WEIGHT X Y 4.25 3 45.96 4.25 3 14 4.25 3 -25.36 4.25 3 45.96 4.25 3 14 4.25 3 -25.36 3.25 28 14 3.25 28 14 3.25 28 60 3.25 28 -60 3.25 41 0 .3.25 41 O· 3.25. 121 14 3.25 121 14 3.25 ' 121 -84 3.25 261 -36 3.25 261 18 3.25 261 18 1. 0625 261 78 1.0625 261 -78

IN THE X AXIS EQUAL-4611.87 IN THE Y AXIS EQUAL 203.1 IN THE Z AXIS EQUAL 6.10352E-OS

ORIGINAL PP.GE IS OF POOR QUALITY

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THE MOMENTS IN THE X AXIS EQUAL-1531.18 THE MOMENTS IN THE Y AXIS EQUAL 294.1 THE MOMENTS IN THE Z AXIS EQUAL 6.10352E-05

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--- ORIGINAL PAGE t3 OF POOR QUALITY

o FT. SQUARE FEET E'EET

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>Jer"11( -17." FOR AN ADDED LENC,TII OF .5 1"'1'1 SURFACE AREA. 2014.41 SQUARE FEET 7Z.,.,lhs t '~3H'1 "P I#f.1 ~-~,t.,9'

I- ,ft.r, VOLUME = 29~1.66 CUBIC FEET LIFT Q 184.589 LDS CIL IS LOCATED AT 148.144 INCHES FROK '1'HE SMALL END

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LIFT a 187.053 LBS CIL IS LOCATED AT 152.198 INCHES FROM '1'IIE SMALL END FOR AN ADD~:!) LENGTI! OF 1.5 FTI • SURFACE AREA. 2045.81 SQUARE FEET 73.'I7/h "C.lfLIJ~t I/'~' -: l"'~~ VOLUME. 3020.2 CUBIC FEET .~ LIFT. 189.518 Lns - ~,." CIL IS I.OCI,TED AT 156.225 INCIIES FROM THE SMALL END FOR AN IIDDf:D LENGTII OF 2 FT. SURFACe A~A • 2061.51 SQUARE FEET

1·1.-I'I"s t fOn,S 1 ~'1.n = -21~-.'3s' ., ",. t, ;-;r.Jf VOLU~E • 3059.47 CUBIC FEET

LIFT. 191.982 LBS CIL IS LOCA'l'ED AT 160.225 INCHES FROK THE SMALL END FOR AN ADDED LENGTII OF 2.5 FT. SURF1\CE AREA" 2077 .21 SQU1\RE FEET '1!:Ol/'st ".l~L'S" '11./1 ~ '4'1.1' VOLum: .. 3098.74 CUBIC FEET 1!J''!i. LIfT. 194.446 Lns -JO,OI CIL IS LOCATED 1\'1' 164.2 INCIIES FROH'1'HE SMALL END FOR AN ADDED LENGTII OF 3 1"'1'1 SUII1'ACE AREA. 2092.91 SQUARE FEET 7.;".1'8 ~"'i'.9fL8S .. ',,",': 'l'H VOLU~:E II 3138.01 CUBIC FEET , ,~, 'il LI F'r • 196.91 LBS -:;,71 CIL IS LOCATED AT 168.151 INCHES FROH THE SMALL END FOR AN ADDED LEt\GTI! OF 3.5 FTI SURFACE AREA a 2108.61 SQUARE FEET ·7t..I'IIJ .. r ';~9'1'8$ 4 IID.J1: -;m.,S­

, ,\~,11 - 'J.J' VOLUME" 3177.28 CUBIC FEET

LIFT II 199.374 Lns CIL IS LOCATED AT 172.078 INCHES FROH THE SHALL END FOR AN ADDED LENGTI! OF 4 1"'1'1 SURFACE AREA. 2124.31 SQUARE FEET 7'.1I1~ -t9'J11.8~ f lV." ~ ·J".~1

f .101.'/4 ~ VOLU~!E .. 3216.55 CUDIC FEET

LIFT. 201.839 LDS CIL IS LOCATED' AT 175.982 INCHES FROH THE SMALL END FOR AN ADDED LENG'l'1I OF 4.5 FT. SURFACE AREA" 2140.01 SQUARE FEET 11.2~/6IT~'3'fL8H 31,S'jJ-llI.",i VOLUME II 3255.82 CUDIC FEET r~Oq.J~ LIFT II 204.303 LDS -'.11 CIL IS LOCATED AT 179.865 INCHES FROM THE SMALL END FOR AN ADDED LENGTH OF 5 1"'1'1 SURFACE AREA. 2155.71 SQUARE FEtT 'II. ~)-Ilu i~'..9'Lts' lUll ~ .1'0 . .1.1

t ;.t'".)) -VOLUME II 3295.09 CUDIC FEET LIFT. 206.767 LDS CIL IS LOCATED AT 183.726 INCHES FROK '1'HE SHALL END

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FOR A CIL LOCA'1ED 144.062 INCIIF.S FROM THE SMALL END. TilE MOMENTS IN THE X AXIS EQUAL-5923 _ 88 JCJ" Ut '1'112 MOMENTS IN THE l! AXIS EQUAL 471.5 THE MOMENTS IN TilE Z AXIS EQUAL-1750.2

FOR A CIL LOCATED 143.H4 WCIIES fROM THE SMALL END. TilE MO/·1ENTS IN TilE X AXIS EQUAL-5835.93 'I'.' L~ TilE ~IOIif::;TS IN '1'11£ Y AXIS EQUAL 471.5 TilE MO~I£Il'rS IN TilE Z AXIS EQUAL-1750.2

FOR A CIL LOCATED 152.198 ItICIIES fROM THE SMALL END. TilE MOMENTS Itl TilE X AXIS EQUAL-5746.17 nnw TilE MOf:EIlTS IN TilE Y AXIS EQUAL 471.5 TilE MOHENTS IN TilE Z AXIS EQUAL-1750.2

. FOR A CIL LOCATED 156.225 II/CIIES FROM THE SMALL END. TilE MCMEIlTS IN TilE X' AXI S EQUAL-5G54.67 "',0' L8j TilE MQ}IENTS IN TilE Y AXIS EQUAL 471.5 TilE MOM EilTS IN TilE Z AXIS EQUAL-1750.2

FOR A CIL LOCATED 160.225 ItICIIES FROM THE Sfo'.ALL El.'D. TilE MCNEN'l'S HI TilE X AXIS EQUAL-5561.42 'III.n L'~ TilE MC~IEN'l'!i IN TilE Y AXIS EC:Ul,L 471.5 TilE MO/·1E/lTS IN TilE Z AXIS EQUAL-1750.2

FOR A CIL LOCATED 164.2 INCIIES fROM THE SMALL Elm: TilE MeHlE/ITS IN THE X AXIS EQU/,L-546G.5S '1!.III.A~ TilE MOHEIITS IN TilE Y AXIS EQUAL 471.5 TilE MO~IEIlTS Ifl TilE Z AXIS EQUAL-17 50.2

FOR A CIL LOCATED 168.151 Il/CUES fROM THE S.,.ALL END. '1'112 MO/·ltNTS IN TilE X AXIS £OUAL-S370.14 .".U l.A~ TilE ttOMJ::NTS IN TilE Y AXIS EQUAL 471.5 TilE MOMENTS IN TilE Z AXIS EQUAL-1750.2

FOR A CIL LOCATED 172.078 Iflcm:s FROM THE SMALL END. TilE ~:om;/ITS lU TilE X I.XI S EQUAL-5272.17 ~CJ 1.1L8~ TilE .,O:tt-;:'TS III TilE Y AXIS EQIJAL 471.5 TilE MOMJ::NTS IN TilE Z AXIS EQUAL-1750.2

FOR A CIL LOCATED 175.982 IfICHES FROM THE SHALL END. THE MOMI::II'1'S III TilE X AXIS EQUAL-5172.71 J&.I1U) TilE MOMENTS IN TilE Y AXIS EQUAL 471.5 TilE MOME~TS IN TilE Z .a,XIS EQUAL-1750.2

FOR A CIL LOCATED 179.865 IIlCIIES FROM THE SHALL END. THE MOM£NTS IN TIlE X AXIS EQUAL-5071.9 3H1L1s TilE .:OI1ENTS IN TilE Y AXIS EQUAL 471.5 THE MOM£IITS IN TilE Z AXIS EQUAL-1750.2

FOR A CIL LOCATED 183.726 nICHES FROM TIlE SMALL END:' THE Mom~NTS IN THE X AXIS EQUAL-4969.67 3'.0' LIS '1'11£ .IO.IENTS IN THE Y AXIS £QUAL 471.5 THE .10~IEIITS IN THE Z AXIS EQUAL-1750.2

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FOR AN ADDED LENGTH OF SURFACE AREA. 2171.41 ~OLUME • 3334.36 CUBIC LIFT. 209.231 LBS CIL IS LOCATED AT 187.568 INCHES FROM THE SMALL END FOR AN ADDED LEIIGTH OF 6 FT:

--:-:-;i:

SURFACE AREA" 2187.11 SQUARE FEET 1,. ~ I~' -t 1c...3~~8H H,<.4 :'-;)'0' .'11

t~.,.~ VOLUME. 3373.63 CUBIC FEET LIFT g 211.695 LDS CIL IS LOCATED AT 191.389 INCHES FROM THE SMALL END FOR AN ADDED LENGTH OF 6.5·FTz SURFACE AREA. 2202.81 SQUARE FEET VOLU:-IE • 3412.9 CUBIC FEET

t .l.IL

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LIFT a 214.159 LBS CIL IS LOCATED AT 195.192 INCHES FROM THE SHALL END

;-r.;-FOR AN ADDED LE~GTH OF 7 FTI SURFACE AREA" 2218.51 SQUARE FEET VOLUME" 3452.17 CUBIC FEET

1(1.11 ,."'C..hLaH~I.'r':. -l07., .

LIFT. 216.624 Lns

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T'tOr CIL IS LOCATED 1.'1' 198.976 INCHES FROK THE SMALL END FOR AN ADDED LENGTH OF 7.5 FTz SURFACE AREA" 2234.21 SQUARE FEET 10.'7/!s"".1'II..8st lr,H ~ -loL.'" VOLONE .. 3491.44 CUBIC FEET .t:!1!1 LIFT" 219.0BB LBS tl",,3 CIL IS LOCATED AT 202.743 INCHES FROM THE SHALL END FOR AN ADDED LENGTH OF 8·FTz

. SURFACE AREA. 2249.91 SQUARE FEET fl. 1:'/" ,,".1"16~ of :Ii." ~ Jflt,J(.

t Jh~''5' -1 Jr. I' VOLum: .. 3530.71 CUDIC FEET LIFT ~ 221.552 LBS CIL IS LOCATED AT 206.493 INCHES FROK THE SMALL END FOR AN ·ADDED LENGTH OF B.5 FTz SURFACE AREA. 2265.61 SQUARE FEET

:1/. 'l11L~ -t 1U'tU\t· il1.C.l~J(\'j.17 ,.J.H ~.l .;.----: VOLU~E • 3569.98 cuaIC FEET

LIFT" 224.016 LDS 1'~.l:r

CIL IS LOCATED AT 210.226 INCIIES FROM THE SHALL END FOR M~ ADDED LENGTII OF 9 FTz SURFACE Am:A • 2281.31 SQUl\RE FEET JI .. ~~ 11~+'l'.'!'1LaS. ~.S"C"JOS' • .1.l VOLl'I.:E • 3609.25 cuaIC FEET H:l.C..'f1 LIFT. 226.48 LaS ~~/.~ CIL IS LOCA'l'ED AT 213.944 INCHES FROM THE SHALL END FOR AN ADDED LENGTII OF 9.5 FTz • J SURFACE AREA. 2297.01 SQUARE FEET 'll.?)·I~·'1~'8.,SJt )r.J1':7').O'l.~_ VOLO~:E .. 3648.52 cuaIC FEET ~ LIFT a 228.945 LDS 1 ;i. 3~ CIL IS Locr.TED AT 217.646 INCHES FROM 'rHE SHALL END FOR AN ADDE:D LENGTH OF 10 FTf SURFACE AREA. 2312.71 SQUARE FEET 1'3.~'1 lilJ t ".'''LUt ,.1f.P.::, .. .llllf.11 VOLUME .. 3687.79 CUBIC FEET . + lJ 1.'11 LIFT. 231.409 LaS ~ • CIL IS LOCATED AT 221.333 INCHES PROK 'rHE SMALL END t .11.1'1 .

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FOR A CIL LOCATED 187.568 INCHES PROM THE S~ALL END: THE MOI·IENTS IN THE X AXIS EQUAL-4866.21 3ot.' 461 THE' MOMENTS IN THE Y AXIS EQUAL 471.5 THE MOMENTS IN THE Z AXIS EQUAL-1750.2

FOR A CIL LOCATED 191.389 nICHES FROM THE SMALL END, THE MOMENTS IN THE X AXIS EQUAL-4761.39 lH1L8S TilE YoOMENTS IN THE Y AXIS EQUAL 471.5 THE MOMENTS I~ THE Z AXIS EQUAL-17S0.2

FOR A CIL LOCATED 195.192 INCHES FROM THE SHALL END, TilE l'!OMENTS IN TilE X AXIS EQUAL-4655.41 31..11£85 THE I.-!CMENTS IN THE Y AXIS EQUAL 471.5 THE Mm:E/:TS Ifl TilE Z AXIS EQUAL-1750.2

FOR A CIL LOCATED 198.976 INCIIES FROK THE SMALL Elm, TilE MO/·IENTS HI TilE X AXIS EQUAL-4548.2 J/.()I..6S TilE MOMEIUS IN TilE Y AXIS EQUAL 471.5 THE MOI{ENTS IN THE Z AXIS EQUAL-1750.2

FOR A CIL LOCATED 202.743 INCflES FROM THE SMALL END: THE H01·:ENTS HI TilE X AXIS EQIJAL-4439.89 1'1.1IfLlj$ TilE MOI1ENTS III ':IIE Y AXIS EQUAL 471.5 THE MOIiENTS IN THE Z AXIS EQUAL-17S0.2

FOR A CIL LOCATED 206.493 IlICHES PROM THE SI'A!.L ENDf TilE MO~ENTS III TilE X AXIS EQUAL-4330.49 l.f.11"$ THE r.OI1ENTS III TilE Y AXIS EQUAL 471.5 TilE Mom:llTS IN THe Z AXIS EQUAL-1750.2

FOR A CIL LOCATED 210.226 n:CHES FROM THE Sl'oALL END, TilE I-:OliENTS IN THE X AXIS EQI1AL-4219.98 17."l.lAJ TilE MOtlENTS IN THE Y AXIS EQUAL 471.5 THE tlOtlENTS III THE Z AXIS EQUAL-1750.2

FOR A CIL LOCATED 213.944 INCHES FROM THE SHALL END. TilE .:OlofENTS IN TilE X AXIS EQUAL-4108.51 z,-r l4S

TilE MOr.I:I~TS IN TilE Y AXIS EQUAL 471.5 TilE IIOp.er-:TS IN THE Z AXIS EQUl\L-1750.2

FOR A CIL LOCATED 217.646 INCIfES FROM THE SHALL ENDf TilE MOMENTS IN TilE X AXIS EQUAL-3996 ls:J'tC.J) THE IIOHEl>TS III TilE Y AXIS EQUAL 471.5 TilE MOHENTS IN TilE Z AXIS EQUAL-17S0.2

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Raven Report No. R01B4-002

APPENDIX H

ST?A Alternate Configuration Analysis

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POINT -WEIGHT X Y 11 4.25 3 45.96 12 4.25 3 14 13 4.25 3 -25.36 14 4.25 3 45.96 15 4.25 3 14 16 4.25 3 -25.36 17 3.25 28 14 -18 3.25 28 14 19 3.25 28 60 20 3.25 . 28 -60 21 3.25 41 0 22 3.25 41 0 23 3.25 121 14 24 3.25 .. 1~1 14 25 3.25 121 -84 26 3.25 261 -36 27 3.25 261 18 28 3.25 261 18 29 1. 0625 261 78 30 1.0625 261 -78

THE MOMENTS IN THE X AXIS EQUAL-4566.57 THE l>lOMENTS IN THE Y AXIS =QUAL 203.1 THE l>10HENTS IN THE Z AXIS EQUAL 6.10352E-OS

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THE MOMENTS IN THE X AXIS EQUAL-5426.03 THE MOMENTS IN THE Y AXIS EQUAL 203.1 THE MOMENTS IN THE Z AXIS EQUAL 6.10352E-OS'

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ORIGINAL PAGE 19 OF POOR QUAL\T'I

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Raven Report No. R0184-002

APPENDIX I

STTA Drawing Package

NOTE: Because of its bulk, this dra\'ling package is included as a separate package with this report.

_ 6_~" _

Raven Report No. R0184-002

APPENDIX J

LDEFI and STTA Serv L:::e Manual

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LDEFl and ST'!'A

SERVl CE MANUAL .

~able of Contents

1.0 List of Special Tools and Equipment Required

2.0 Inflation and Assembly of the LDEFI

3.0 Inflation and Assembly of the STTA

4.0 Daily Servicing

5.0 Periodic Maintenance

6.0 Leak Detection

7.0 Leak and Damage Repair

8.0 Storage

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SERVICE MANUAL

r 1.0 LIST OP SPECIAL TOOLS AND EQUIPMENT REQUIRED

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The following is a complete list of tools and equipment r£quired to inflate, assemble, attach equipment, repair and maintain these inflatables.

19016. Equipment

Main inflation port adaptor Main inflation hose with regulator Servicing hose ,with dill valve adaptor Pressure gauge with range of 0 to 5 inches of H20 Pressure gauge with range of 0 to 3 psi ,/16 inch hex socket or open end (for 1/4 inch-20 attaching

bolts) Scissors Acid brushes Rubber gloves Sponges and pail Roller

Consumable Supplies

Bostik 7133 adhesive (patching adhesive) Reeves Hl19-099 adhesive (Velcro adhesive) THP activator Patching material Compressed helium

2.0 INFLATION AND ASSEMBLY OF THE LDEFI

2.1 The LDEFI is composed of the following pieces:

1 main envelope 2 tori 2 end skirts 2 round end panels 6 gross ballast shot bags

2.2 Inflation and ~m~ reguire a minimum Qf tx2 Jll people. Begin by inflating the main envelope and two tori with helium. To inflate the main envelope, attach a large hose to the large port on the main servicing panel and fill to a pressure of three .ill ill£h~ 2f ltall.I. pressure. Fill the tori by attaching a small hose with a dill valve adaptor to the dill valve on the torus. Service the tori to a pressure of ~~ ill Eli.

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LDEFI/STTA SERVICE MANUAL

NO'l'B ORIGINAL PAG~ i9 OF POOR QUALITY

Prior to inflation, remove as much air as possible from the envelopes to ensure maximum lift when inflated.

WARNING

Use great caution. Bellum is usually under extremely high pressure, up to 3,000 psi. Pressurized gases contain a great deal of potential energy and can be dangerous.

2.3 Match the torus marked -ForwardR with the end of the main envelope marked RForward. R Find the Velcro strap on the torus with the number that matches a convenient attaching patch on the main envelope. Attach the Velcro strap so that the black mark lines up with the end of the Velcro on the main envelope (see Figure 2.1>.

Move around the balloon attaching each strap in the same manner. When complete, attach the remaining torus to the opposite end in the same manner.

2.4 Identify the skirt marked RForward.R Locate the black marks on the Velcro of the torus and main envelope of the forward end. Attach approximately ~.4 inches to the envelope Velcro. Then attach to the torus ~nvelope. Continue around the balloon in the same manner until the skirt is attached.

BOTB

Uneven pressure on the Velcro during installation will cause wrinkling and uneven stretch.

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LDEFI/STTA SERVICE MANUAL

If the ends of the skirt are uneven or do not meet, return to starting point and rest retch Velcro on each edge around the balloon. Attach the remaining skirt in the same manner on the opposite end.

2.5 Identify the round end panel marked -Forward.- Locate the black mark on the Velcro. and the corresponding mark on the Velcro of the forward torus. Move around the circumference of the panel, attaching it to the Velcro. To verify proper orientation, check tnac access patches are directly in front of servicing ports. Attach remaining panel to opposite end in same manner. .

3.0 INFLATION AND ASSEMBLY OF THE STTA

3.1 The STTA is composed of the following pieces:

1 forward end main envelope 1 aft end main envelope 5 tori 5 skirts 4.round end panels 1 mid panel 6 gross ballast shot bags

3. 2 .Infl.a.t.i~m Ami A.s~m121~ ll911.ill .a min.imllm 2L .t.hu..e ill people. Begin by inflating the main envelopes and five tori with helium. The main envelopes may be filled by attaching a large hose to the large port on the main servicing panels. The tori may be filled by attaching a small hose with a dill valve adaptor to the dill valve on the torus. The envelopes should be inflated to the following pressures:

Forward main envelope -Aft main envelope Large torus (1) Mid torus (1) Small tori (3)

NOTE

Prior to inflation, remove as much air as possible from the envelopes to ensure maximum lift when inflated.

kARR:IRG

Use great caution. Belium is usually und~r extremely high pres3ure, up to 3,000 psi. Pressurized gases con~ain a great deal of potential energy and c~ be dangerous.

3.3 To begin attaching the tori, s~lect the large torus and match it up with the aft end of the aft envelope. Find the

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LDEFI/STTA SERVICE MANUAL ORlGlr':AL PA~t: '9 OF POOR QUALITY

corresponding mark on the Velcro of the aft end torus. Move around the circumference of the panel attaching it to the Velcro. Verify correct orientation by checking that access panels ti.re directly over servicing ports. In the same manner, attach the remaining end panels and the mid panel. Both Velcro index marks on the mid panel must be matched to ensure that no·twist has been induced in the material.

3.6 To hook forward and aft section together, match the two ends so the trunnion mounts are all in line. Then turn both ballo.~s so the top attaching points are accessible. Attach a turn buckle to each point. The ballouns are now connected at the ~~ ~2int 2nl2 (1 of 6). Turn the balloons back to the normal orientation. Adjust the position so that the two halves line up. When a proper alignment is achieved, attach a turn buckle to each side simultaneously. Install the remaining three turn buckles and adjust as necessary to ensure that the center lines are nearly parallel.

4.0

4.1

DAILY SERVICING

The STTA and LDEFI should be serviced daily to prevent total loss of skin tension which could c~use bending of the objects and possible misalignment of tori, skirts and end panels. If the objects are not in active use, they need only be se~viced to one-half (1/2) of normal operating pressure. This reduces stress and lengthens fabric and

. coating life.

The following is a summary of operating pressures for each object: (See Figures 4.1 and 4,2 for servicing locations of the LDEFI and STTA, respectively.)

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LDEFI

Main envelope - 3- H20 Tori - 1 psi (28- H20)

t' ___ 'i.,.' _----- It,.,,, LIf" S£.R.~/CIN& 3-H .. O

,,- (,I

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1--------101\IIS S£ltr/G/Nt.

" 29" UaD _ .

Figure 4.1

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LDEFI/STTA SERVICE MANUAL

STTA

Forward main envelope - 4- H20 Aft main envelope - 3 w H.O Large torus - .25 psi (7~ H20) Mid torus - .5 psi (14 W "20T 3 small tori - 1.25 psi (35· H20)

SMALL To,.,' ];"

Figure 4.2

No other servicing is required.

5.0 PERIODIC MAINTENANCE - None

6.0 LEAK DETECTION

Three types of leaks may ~e found in helium inflatables: Micro leaks, small pinhole leaks and large leaks.

6.1 Micro leaks are often caused by minute holes. They may not take a direct path through the material but rather find a series of channels by which to escape. It is very difficult to find these leaks. A special apparatus must te used to detect the presence of inner gases. .Such leaks do not present a problem for articles such as the STTA and LDEFI because theit operating time between servicing is short.

6.2 Higher than usual loss rates for a particular envelope are the first indication of pinhole leaks. Most small pinholes will not allow enough gas to escape to need servicing more often than the required eight-hour operational period, but they should be identified and repaired. If the proximity of the leak is known, Liquid Snoop (provided in the repair kit) may be used to ,identify its exact lo~ation. If the proximi ty is unknown, the envelope may be leak-checked by going over the balloon section-by-section with a soapy water solution and watching for bubbles.

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LDEFI/STTA SERVICE MANUAL

6-.3 Large leaks are those too large to be *de.tected with soapy water. High air flow blows away all the soap solution before bubble films can form. Loss of gas in a relatively short time is evidence of such leaks. The best way to locate these leaks is by sound and touch. The face tends to be more sensitive to the air flow than the hands.

7.0 LEAK AND DAMAGE REPAIR

7.1 Once a leak has been located, or if a tear has occurred, lower the pressure of that envelope to below 0 psid.

CAUTIOR

If a repair is attempted while the balloon is pressurized, the area to which glue is applied may become completely porous.

CAUTIOR

The adhesive and activator are hazardous aaterials. Read the labels on the cans and the enclosed safety data sheet before using.

A hole or damaged area can be repaired by making a fabric patch which, if possible, overlaps the damaged area on all sides by three inches. Apply adhesive with a small paintbrush to both the patch and damaged area. Allow the adhesive to dry completely. Apply a second coat of glue. When the second coat has dried, use a cloth to apply the activator to the adhesive on both the patch and the balloon. This seals the patch to the balloon.

When repairing a long tear, activate the glue on only a portion of the balloon and the patch at one time. The portion which has been activated should then be pressed to the envelope and rolled in place with the roller provided. Continue this process until the entire patch has been secured to the balloon.

The adhesive provided, Bostik ~, bas a shelf life of six (6) months. Once the shelf life has been passed, the adhesive may not dry properly, and this may enlarge the damage area.

B.O STORAGE

B.l If the envelope is stored inflated or partially inflated, the pressure should be kept near or below 0 psid to provide longest cervice life.

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LDEPI/STTA-SERVICE MANUAL

8.2

CAUTION

Changes in atmospheric pressure Ilay cause overpressurization of some or all of the envelopes.

If the balloon is deflated and packed in a crate, use extreme care to ensure that hardware does not damage the fabric. The envelope should be folded and stored in a low or normal humidity area at temperatures between SOop and 80oP.

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End of Document