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Production zones for Ariane stages

The booster zone

In order to carry out the activities laid down in the programme for the European Ariane 5 launcher, the Guiana Space Centre built its own factory for local production of launcher elements.
This zone groups together three sites which are involved in preparing, assembling and testing solid-propellant boosters.

The Guiana propellant plant (UPG)

Covering 300 hectares, the manufacturing and loading of solid propellant for the solid-propellant booster stages is divided between 40 buildings (© ESA/CNES - Photo CSG/Service Optique)

The Ariane 5 launcher has two booster stages (EAP) located on either side of the main cryogenic stage (EPC). Each booster consists of three segments (front, centre, rear). Each booster stage weighs 270 tonnes and yields a thrust of 600 tonnes on lift-off for the generic version.

The Guiana propellant plant (UPG), created in 1992, is run by the French-Italian company, Regulus. It manufactures the solid propellant and loads it into two of the three segments (centre and rear) of the booster stages. The third, the front segment, comes from Italy.

Ultimately, the maximum the UPG may be able to produce 32 to 40 segments per year.

Booster engine test stand (BEAP)

This test stand was designed for the development and qualification of solid-propellant boosters. It has a unique design with a 50 m high tower standing on a pyramid-shaped concrete base; the base is perched over a flame chute cut 60 metres deep into solid granite, with a length of 200 metres and a width of 35 metres.
It is used to test the various booster specimens in their flight position and can withstand a thrust of 1,350 tonnes. Eleven tests were performed between 1993 and 2005.

Booster integration building (BIP)

The different booster segments are moved on a specially designed, heavy-weight trailer from the Guiana propellant plant to this building where they are prepared and assembled in a vertical position on their pallets (to which they remain attached throughout the preparation phase until lift-off). The segments are then prepared and equipped by the French-Italian Europropulsion company.

The functional equipment for the main cryogenic stage (EPC) for Ariane 5 (fairing, flight control system, electrical and pyrotechnic systems, fastening system) are integrated into the boosters by EADS Space Transportation.

Once they have passed functional tests, the booster stages are transferred either to the launcher integration building (BIL), 2.8 km to the North, or to the booster engine test stand (BEAP) located 1 km to the South, for other tests. They may be transferred on pallets, by train or with a specially designed 180 tonnes, mobile platform.

Booster storage building

The booster storage building, located between BIP and BIL, was built to avoid any random production hazards at the booster integration building from delaying the launch schedule. Since the two operational units used the same test facilities, booster stages were previously delivered at different times. This building is now capable of storing four booster stages which means the production team can stay one step ahead.

Booster logistics building

The booster logistics building made available to Europropulsion (with ESA financing), covers a surface area of 1,600 m2 and is used for efficiently performing a number of activities. The building is divided into four zones, each for a defined function:

Acceptance and packaging of components, tools and jigs
A general store for spare parts, consumables and nozzles
Preparation of equipment and measurement devices
Maintenance of components, tools and jigs

EXPLOITATION AND BOOSTER CASING PREPARATION BUILDING (BPE)

The booster casing preparation building (BPE), which has been in operation since November 1996, is 70 m long, 20 m wide and 15 m high. The building is managed by EADS Space Transportation which prepares the upper and lower parts of the booster stages at the same time as operations being conducted by Europropulsion in the launcher integration building. It is in the BPE that the nozzle actuators and parachutes for retrieving the boosters at sea, etc. are installed.