Saturn S-IC Construction

7/27/2019 Saturn S-IC Construction

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BELLCO_, INC.

SU_ECT: Description of the S-IC StageStructure - Case 330

DAT:FROM:

February 2, 1967S. H. Levine

ABSTRACT

The purpose of this memorandum is to provide a descrip-tion of the S-IC stage structure in sufficient detail such thatthe user of this information can be better equipped to Judge theimpact of changes to these areas as they occur in the program.

This information is in essence a compendium of dataand drawings compiled from various Boeing Company and MSFCdocumentation which includes design requirements documents,manufacturing plans, end item specifications and other datasources.

H79-72161(_ASA-CR-153761) DESCRIPTION OF THE S-ICSTAGE STRUCTURE (Bellcomm, Inc.) 29 p

_nclas00/15 12_17


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BELLCOMM, INC.

SUBJECT: Description of the S-IC StageStructure - Case 330

DATE:

FROH:

February 2, 1967S. H. Levine

MEMORANDUM FOR FILE

PURPOSEThe purpose of this memorandum is to provide a descrip-

tion of the S-IC stage structure in sufficient detail such thatthe user of this information can be better equipped to Judge theimpact of changes to these areas as they occur in the program.GENERAL

The S-IC stage is composed of five principal assemblies,namely, the Forward Skirt (Unit 120), the Oxidizer Tank (Unit 119),the Intertank (Unit 118), the Fuel Tank (Unit 117) and the Tallor Thrust Section (Unit 115). Figures i through 4 are presentedto illustrate the general composition, the physical dimensions andsome other general characteristics of the S-IC stage.Forward Skirt Structure (Figures 5 and 6)

The forward skirt is an unpressurized semi-monocoquecylindrical structure approximately i0 feet long and 33 feet indiameter. This structure is composed of three internally locatedCircumferential Support Rings upon which are mounted 12 Skin PanelAssemblies.

The Circumferential Support Rings (3) are constructedof 7079 aluminum alloy and are made up of six segments joinedtogether in a circular form. The purpose of these rings is tomaintain the circular shape of the forward skirt. The topmostring, the Interface Ring, an inverted L shaped cross sectionedunit, provides the S-IC structural interface at which the S-IIaft interstage is physically spliced to the S-IC Forward Skirt(at vehicle station 1541.0 inches). Two-hundred sixteen - 1/2inch diameter holes drilled on a 394.340 inch diameter circleprovide the mechanics for bolting the S-If stage to the S-IC.*The center ring is called the Channel Ring and is approximately7.5 inches across the web. The bottom-most ring has a J shapedcross section and is appropriately called the J Ring.

*Crowe, T. H. - "Description of S-II Stage Structures" -Memorandum for File

Available to NASA 0 "'rflces and,Research Centers Only,


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BELLCOMM, INC. - 2 -

The Skin Panel Assembly is composed of a lower section(below the Channel Ring) which is cylindrical in form and anupper section which is an inverted truncated cone having aslope of 036 ' The 12 skin panels forming the Skin PanelAssembly are reinforced by 216 external hat-shaped stringerswhich are spaced on 5-3/4 inch centers ana span the fulllength of the skirt. These stringers transmit the stagelongitudinal loads to the S-II stage via the Interface Ring.The skin panel assembly is made up entirely of 7075-T6 aluminumalloy.

Provision is made for mounting S-IC Telemetry Equip-ment, Range Safety System Equipment, ODOP System Equipment, theLOX tank pressurization tunnel and the electrical cable tunnelin and on the Forward Skirt. In addition, the Forward Skirthas provisions for the GOX to ground system interface, theoxidizer tank vent to ground interface, a service access hatchand the S-IC forward umbilical plate (interface with S-ICForward Umbilical Tower Service Arm #I at LUT elevation 60 ftand located 73 from vehicle position I towards position II).Oxidizer Tank Structure (Figure 7)

The oxidizer tank is a 64 foot assembly having acapacity of 345,000 gallons, and is constructed of 2219-T87weldable aluminum alloy. This assembly consists of a 396 indiameter cylindrical central assembly capped and welded atboth ends by means of Y shaped rings (one upper and one lowerring) to convex ellJpsoidal bulkheads.

The Cylindrical Skin Section Ring Assembly is asemimonocoque structure which consists of 4 - i0 ft high skinpanel rings which are welded together circumferentially.

Each skin panel ring is in turn made up of 4 weldedpanels which are approximately i0 feet high by 26 feet long.The entire assembly's general skin thickness varies from.185 inches at the top to .254 inches at the bottom. T shaped2 inch high vertical stringers spaced on 7.4 inch centers areintegrally milled over the full length of the inside of thisassembly. The cylindrical section of the oxidizer tank formsthe outside skin of the S-IC stage between the Forward Skirtand the Interstage. Fifteen annular anti-slosh baffles con-structed of 7079 aluminum alloy are mounted in the cylindricaland bulkhead sections of the LOX Tank. The 13 baffles whichare mounted in the cylindrical section measure .040 inchesthick x 33 feet O.D. x 28 feet I. D. The 2 cantilever baffleslocated in the bulkheads are slightly smaller in diameter. Inaddition to preventing slosh, these baffles supported byaluminum tubing also assist in stabilizing the tank structure.


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There are five Ring Frames constructed of I beamshaving web planes perpendicular to the longitudinal axis ofthe launch vehicle and spaced on 49.5 inch centers whichmaintain the circular shape and provide stability to theskin panels of the Intertank.

Openings and hatches are provided in the Intertankskin for personnel access, for two static test fuel vent linesand for one flight vent line. In addition, provisions aremade for one static test fuel pressurization line, one flightfuel pressurization llne, a LOX emergency drain valve lineand its pneumatic control llne, and finally the LOX fill andreplenishment umbilical (located at station 785.15 and 73 from vehicle position I towards vehicle position II). TheLOX fill and replenishment umbilical interfaces with the S-ICIntertank Umbilical Tower Service Arm on the LUT.

Fuel Tank Structure (Figure 9)The 216,000 gallon Fuel Tank structure is approxi-

mately 43 feet long and 33 feet in diameter and is constructedsimilar to the LOX tank. The entire fuel tank shell, consistingof a cylindrical section assembly enclosed on both ends by twoconvex ellipsoidal bulkheads, is manufactured of 2219-T87 weldedaluminum alloy. Bulkheads are Joined to the cylindrical sectionby welds at Y Rings located at the top and bottom of the assembledcylinder.

The Cylindrical Skin Section Assembly consists of twocylindrical sections welded together. Four skin panels joinedin cylindrical form make-up each skin section. Each panel isapproximately I0 feet high by 26 feet long. 51 - 2 inch highvertical T shaped stringers are integrally milled on the insidesurface of each skin panel and are spaced on 6.10 inch centers.These stringers provide stiffness to the structure and transmitloads from the Thrust Structure to the Intertank. The skinthickness of the assembly generally varies from .170 to .193inches, forward to aft. This section of the Fuel Tank formsthe outer surface of the S-IC Stage between the Interstageand the Thrust Structure.

There are 9 annular anti-slosh baffles constructed ofaluminum alloy, seven of which are mechanically attached to theT stiffeners on the interior surface of the cylindrical sectionof the fuel tank and two of which are cantilevered from the innersurface of the bulkheads (one baffle per bulkhead). The annularbaffles are generally .040 inches thick x 33 feet O.D. x 28 feetI.D., however, the cantilever baffles are slightly smaller insize. Rigid tubing is provided for additional support of thesebaffles.


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The Y Rings (2) which Join the bulkheads to theCylindrical Skin Section Assembly also provide the mechanicalJoint which unites the Fuel Tank to the Intertank Structureand the Thrust Structure. Holes are located in the Upper YRing to permit drainage of the Intertank area.

The Fuel Tank Bulkheads (forward and aft_ conform toan ellipsoidal major axis to minor axis ratio of 2 and eachare assembled by welding eight apex gore sections to eightbase gore sections (Figure 7).

Five LOX Tunnel Assemblies are 22 inches in diameterand carry the five 20 inch diameter LOX suction lines from theaft bulkhead of the LOX tank through both Fuel Tank bulkheadsto the Thrust Structure area of the S-IC Stage. LOX lines (5)are reduced to 17 inches in diameter at tunnel outlets in theThrust Structure area. Stiffener rings are provided aroundthe tunnels for structural rigidity. In addition to providingsupport for the LOX suction lines the LOX Tunnels provideFuel Tank insulation from these cryogenic fluid lines and visaversa.

The Upper Bulkhead of the Fuel Tank has five pene-trations for LOX tunnels, one slightly off the centerline ofthe S-IC stage to avoid fuel fittings located in close proxi-mity to the centerline of the dome, and the rest located at45 intervals from each vehicle position location. LOX tunnelsare mechanically linked to the forward dome of the Fuel Tank.Four 18 inch diameter armholes (one at each vehicle positionlocation) are provided in the Upper Bulkhead. One fuel ventvalve is mounted to the manhole cover at vehicle position Iand two facility vent valves are located on the manhole atvehicle position III. In addition, a removable gaseous heliumdistributor which distributes gasified helium from the engineheat exhangers to the fuel tank for flight pressurization isprovided.

The Aft Bulkhead contains an internally locatedcruciform baffle constructed of 7075 aluminum alloy and usedto minimize vortexing and sloshing in the lower part of thefuel tank. An exclusion riser (essentially a filler of theapex area of the bulkhead) constructed of polyurethane foammaterial, is located centrally at the lowest part of the bulk-head and is used to prevent entrapment of fuel below the levelof the fuel suction line fittings and thereby reduces S-ICStage unusable fuel. Five 22 inch penetrations are providedin the Aft Bulkhead where the LOX tunnels passing through theFuel Tank are welded. The Fuel Tank Aft Bulkhead also providesfor the attachment of ten-12 inch diameter fuel suction lines


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B i_I..I..CO M M, INC. - 6-

(2 per engine) with screens and antl-vortex devices at fuelsuction line inlets to reduce vortexing at these points.In addition, the Aft Bulkhead provides for one-6 inch dia-meter fill and drain line and associated hardware (normaldraining of the fuel tank is conducted using equipment commonto the fuel fill system) and for one emergency Fuel DrainLine used only for test stand operations.Thrust Structure (Figure i0)

The Thrust Structure, the most complex and heaviestof the five major S-IC structural units, is an unpressurizedcylindrical semimonocoque structure which is approximately33 feet in diameter and 19.5 feet long. This portion of theS-IC Stage is designed to support four outboard gimballed F-1engines on a 364 inch diameter circle and one inboard fixedF-I engine on the centerline of the launch vehicle. Allengines are arranged in the same vehicle station plane. TheThrust Structure functions to symmetrically distribute locallyapplied engine loads and holddown and support reaction loadsto attain uniform symmetrical loading along the Fuel Tank AftY Ring (see previous discussion).

The Center Engine Support Assembly (Figure Ii) isa crucifix form consisting of four stiffened web assemblies(capped and Joined together on top and bottom by tee shapedbeam caps and stiffened by vertical and horizontal stiffeners)which are arranged radially along vehicle position lines andmechanically mated at the center to a vertical Center EngineThrust Post to which is mounted the inboard fixed F-I Engine.The stiffened webs and caps are constructed of 7178 AluminumAlloy and are each approximately 3/8 inch thick by 78 incheshigh by 175 inches long (excluding the beam caps). TheCenter Engine Thrust Post is constructed of forged 7079Aluminum Alloy.

There are four Holddown Posts located on the outerperiphery of the S-IC Thrust Structure at each vehicle positionand mated to the Center Engine Support Assembly. These postsare constructed of a one piece 7079 aluminum alloy forgingwhich is approximately 14 feet high and II inches square atthe base (not including the flange which ties the Holddown Postto the Thrust Structure Skin) tapering to a smaller cross sec-tion at the top. Each Holddown Post is joined at the forwardend to an Upper Thrust Ring and at the aft end to a Lower ThrustRing (to be discussed later). Thrust loads are transmittedfrom the Center Engine Thrust Post through the radial arms ofthe Center Engine Support Assembly up through the four HolddownPosts and finally to the Upper Thrust Ring where it is thensymmetrically distributed to forward sections of the vehicle,


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I

Holddown Post positions are coincident with the LUT HolddownArm positions (North, South, East and West) and the vehicleis held and restrained to the launch pad from these points.

Located approximately 45 from Holddown Posts onthe outer perimeter of the Thrust Structure are four out-board engine vertical Thrust Posts. The Thrust Posts (Figure 12)are built up box type cross sectional units which are 36 inchesby 39 inches at the base (common with the Lower Thrust Ringattach surface) and taper to a 14 inch by 22 inch cross sectionat the top (the Upper Thrust Ring). These posts, which are thelongest lead item of the S-IC stage, are 14 feet high and areconstructed entirely of machined 7075-T6 aluminum alloyforgings. Each post is mechanically fastened to the Upper andLower Thrust Ring as well as to each Intermediate Ring of theThrust Structure (see discussion below). Outboard gimballedF-I engines (4) are mated to the thrust posts by means ofadapter fittings tied to engine gimbal blocks.

The Upper Thrust Ring is constructed of 7079Aluminum Alloy and is 30 inches wide and annular in form.This ring consists of a 3/16 inch thick web plate bridgingtwo circular tee shaped beam caps (one outboard and one inboard)and is reinforced by radial stiffeners.

Intermediate Ring Assemblies (Figure 13) made of 7079aluminum alloy are smaller in size than either the Upper orLower Thrust Ring. These rings are spaced approximately 32inches from each other and are located between the Upper andLower Thrust Rings. These rings too are made up of web plateswhich bridge beam caps. The beam caps used for the IntermediateRings have angle cross sections and while the outboard anglebeam cap conforms to the perimeter of the stage, the inboardangle beam cap is linear and connects Thrust Posts to HolddownPosts. Radial support stiffeners are also provided to rein-force these rings. Stiffened intercostal assemblies (32) arelocated between the upper and lower pairs of IntermediateRings (16 per pair) for additional support and stability forthe Intermediate Rings.

The lower Thrust Ring Assembly is an annular ringconstructed of 7079 aluminum alloy and is approximately 40inches wide. This ring consists of inboard and an outboardtee shaped caps bridged by and mechanically fastened to a 3/8inch thick Web plate which is reinforced from beneath by radialtee cross sectional stiffeners. The outboard tee shaped beamcap forms the outer surface of the S-IC stage at the locationof the Lower Thrust Ring. The Lower Thrust Ring in coordinationwith the Thrust Posts supports retrorockets (2 per fin location)which are used for separating the S-IC from the S-If.


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" . BELLCOMM, INC. - 8 -

The Skin Panel Assembly consisting of 16 skin panelsspliced together by hat-shaped external skin splices and con-structed of 7075-T6 aluminum alloy forms the outside surfaceof the Thrust Structure from the interface with the Fuel Tankto the Lower Thrust Ring. Approximately 19 feet high andcylindrical in form the Skin Panel Assembly varies in thick-ness from .210 inches at the forward end to .680 inches at theaft end and is reinforced by mechanically attached externalvertical hat-shaped stringers.

Provisions are made for cutouts for a 6 inch diameterdrain duct from the inboard LOX suction line (above the prevalve)for a 6 inch diameter fuel fill and drain line and for an emer-gency fuel drain line (test stand usage only). Three aft life-off umbilical panels exist which are all located at vehiclestation 135.75 and umbillcals attached to these panels are re-tracted upon a vehicle rise of 3.6 inches. These umbilicalsinterface with the LUT Tail Service Masts and are located asfollows: two at 12 39' 22-1/2" from vehicle position I towardsII and one at 12 39' 22-1/2" from vehicle position III towardsIV.

Two aluminum, external, V-shaped tubular appendagesto the cylindrical section of the Thrust Structure each linkedto the Thrust Structure by an aluminum tube which extends for-ward and is tied to the Skin Panel Assembly provide a trussarrangement which is used to support the S-IC Flight ControlSystem gimbal servo actuators. These appendages are locatedon either side and in close proximity to each Engine ThrustPost and are enclosed by Engine Fairings (to be discussedbelow).

Four Fin and Fairing Assemblies (Figure 14) arelocated around the periphery of the S-IC Thrust Structure (oneat each outboard engine location). Each Engine Fairing con-sists of a semi-conlcal shaped structure which has a basediameter of 166.50 inches, is approximately 8 feet deep whenmounted on the S-IC Thrust Structure and has a slope of approxi-mately 15 . This structure extends from vehicle station 48.5to vehicle station 362 (approximately 26 feet long). Theengine falrings function to prevent infllght aerodynamic loadsfrom interfering with engine movement, to provide protectivecover for F-I outboard engines, to support aerodynamic fins,to house S-IC retrorockets used in separation (2 per fairing)and to provide protective covering for elements of engineaccessories and the S-IC flight control system. The lower5-1/2 feet of each fairing is constructed of titanium alloywhile the rest of the total assembly is manufactured ofaluminum alloy. Aluminum and titanium sections are Joinedat a Fin Spar Attach Frame (see Figure 15).


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BEL.LCOMM, INC. - 9 -

The forward 12 feet of the Engine Fairing Assembly isconsidered the Upper Fairing while the lower 14 feet is appro-priately called the Lower Fairing. The Fin Spar Attach Frame(previously mentioned) provides the basic structural tie betweenthe cylindrical Thrust Structure and the Fairing and betweenthe aerodynamic fin and the Fairing. The Fin Spar Attach Frameconsists of two machined aluminum plates Joined at the centerby a steel fin spar attach fitting and fixed to the ThrustStructure by steel thrust structure attach fittings at eachend. Six llnk fittings are also provided for attaching thelower fairing to the Thrust Structure Assembly. Four Titaniumalloy frame assemblies are provided below the Fin Spar AttachFrame in the Lower Fairing Assembly at intervals of about1-1/2 feet while three aluminum frames spaced at 2-1/2 footintervals exist above the Fin Spar Attach Frame. These framesare used for structural stability. The major structural frameof the lower four is the truss frame located 1-1/2 feet fromthe bottom of the lower fairing. This frame contains a trussconsisting of welded hastelloy tubes and plates for structuralrigidity. Intercostals are provided between frame units foradditional structural support. Closeout channels are fastenedto the ends of these frames linking them over the full lengthof the Lower Fairing. Skin covering the lower fairing isstiffened by longitudinal L shaped external stiffeners. TheUpper Fairing, which is removable for access to retrorocketsmounted on the Thrust Structure, consists o three frame as-semblies, closeout channels, and intercostals similar to theLower Fairing. Skin reinforced by L shaped external verticalstringers also covers the Upper Fairing Assembly. Air scoopsare mounted to the Lower Fairing on early versions of theS-IC (S-IC-I and 2), however, the need for this thermal controlhas been eliminated on subsequent vehicles.

Externally attached to each engine fairing at thecenterllne of the seml-conlcal structure is a rigid aerodynamicfin assembly (Figure 16) having a sweep back angle of 30 degreesand having a surface area of 75 square feet. Fins have beenadded to the S-IC stage to provide aerodynamic stability duringfirst stage flight of the Apollo-Saturn Space Vehicle. Fins areidentified as follows: Fin A (between vehicle position I and II),Fin B (between vehicle position II and III), etc. Each fin mea-sures approximately 11-1/4 feet high (at the root), and is 15inches wide at the root and 4 inches wide at the outboard end.External components of the Fin Assembly are constructed oftitanium alloy while internal components are made of aluminumalloy. The fin spar which Joins the forward section of the finto the aft section of the fin is the major structural pointmechanically tying the fin to the Engine Lower Fairing Assembly


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(at the Fin Spar Attach Fitting - see above). There are tennose ribs, one tip nose rib, and one root nose rib Joining theleading edge beam to the spar and forming a leading edge wedgeangle of i0 . The aft section of the fin, from the spar tothe trailing edge beam is essentially rectangular in crosssection and also consists of ten trailing edge ribs, a roottrailing edge rib and a tip trailing edge rib. The leadingedge beam has a leading edge radius of 1/4 of an inch and isconstructed entirely of titanium alloy as is the trailing edgebeam. The Spar Assembly and the Trailing Edge Beam Assemblyeach are comprised of two chords Joined together by a web andstiffeners The Spar Assembly protrudes from the basic finprofile at the root end where it is bolted to the engine fairing.Skin panels cover the fin rib and spar assemblies and closureangles and bolts splice the skin at the root of the fin to theengine fairing.

MISCELLANEOUS STRUCTURESI

A base heat shield (Figure 17) consisting of fifty1/4 inch panels (at approximately vehicle stationii0) is provided forward of the engine gimbal planewhich provides thermal protection of critical enginecomponents and base region components during launchand flight. Access panels are provided in eachquadrant of the heat shield for servicing the thruststructure and engine areas. The heat shield is con-structed of fifteen 7 ph stainless steel open-facedhoneycomb and is covered with M-31 insulation. Padsare provided on the thermal shield (bonded in placeon the insulation) at vehicle positions II and IVfor liftoff switch roller follower interfaces.Flexible curtains are provided for closeout of heatshield gaps at propellant line interfacesEngine Fairing Heat Shields (4) provide a thermalprotective barrier for the innards of the enginefairings. Made up of eight panels each and con-structed of the same material as the base heatshield, each fairing heat shield is mounted tothe thrust structure in llne with the base heatshield and tilted down in a plane at an angle of7 14' where it extends and is Joined to and sup-ported by the Fin Spar Attach Frame of the EngineFairing Assembly.

Two tunnel assemblies constructed of aluminum aremounted to the external surface Of the S-IC stage.Each is seml-elliptical in cross section (approxi-mately 1 foot x 2 feet) with a hyperbolic fairingat each end and extends from vehicle station 180 in


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. BELLCOMM, INC. - ii -

the Thrust Structure to vehicle station 1538 in theForward Skirt. The Pressurization Tunnel houses,protects, and supports pressurization lines betweenthe Thrust Structure (location of the F-I engine heatexchangers) and S-IC stage penetration points at pres-surant usage locations (propellant tank domes). Thistunnel is located II 15' from vehicle position IIItoward Fin C. The Electrical Tunnel is designed tohouse, protect and support electrical wiring fromthe Forward Skirt to the Thrust Structure and pres-surization lines from the helium pressurizationbottles located in the LOX Tank to the Thrust Struc-ture. This tunnel similar in design to the Pressuri-zation Tunnel is mounted 180 from the pressurizationtunnel on the periphery of the S-IC stage. Bothtunnels are supported from the S-IC Stage by supportfittings spaced at 40 inch intervals in the propellanttank area of the stage and fittings tied to the S-ICinner structural frames in all other areas.

1024-SHL-gdn S. H. LevineAttachmentFigures i - 17Copy to(See next page)


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Copy toMessrs. I. Davids - NASA/MAT

I. E. Day - NASA/MATJ. H. Disher - NASA/MLDL. E. Fero - NASA/MLVJ. P. Field - NASA/MLPT. A. Keegan - NASA/MA-2M. Savagh - NASA/MLTW. B. Shapbell, Jr. - NASA/MATG. C. White, Jr. - NASA/MARC. BidgoodT. H. CroweD. R. HagnerW. C. HittingerB. T. HowardJ. Z. MenardI. D. NehamaJ. J. O'ConnorT. L. PowersI. M. RossW. StrackT. H. ThompsonR. L. WagnerCentral FilesDepartment I02__Library


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NO. AREADEFINITIONENGINE I COMPARTMENTENGINE 2 COMPARTMENTENGINE 3 COMPARTMENTENGINE q COMPARTMENTENGINE 5 COMPARTMENTBASE HEAT SHIELDENGINE FAIRING) FIN AENGINE FAIRING, FIN BENGINE FAIRING, FIN CENGINE FAIRING, FIN DFIN AFIN BFIN CFIN DTHRUST STRUCTURECOMPARTMENTCABLE/PRESS TUNNEL AREASFUEL TANK AREAINTERTANK COMPARTMENTOXIDIZER TANKFORWARDSKIRT AREA 116 117 116

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FIGURE 3 S-IC STAGE AREA DESIGNATIONS


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