AOD 33973

Rev C 

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SUPER GUPPY TRANSPORT 

USER’S GUIDE 

Aircraft Operations Division

May 2023

Public Release Statement: This document has been reviewed for Proprietary, SENSITIVE BUT UNCLASSIFIED (SBU), and 

Export Control [International Traffic in Arms Regulations (ITAR)/Export Administration Regulations (EAR)] and has been 

determined to be non-sensitive. It has been released to the public via Scientific and Technical Information process, DAA 40402.

National Aeronautics and

Space Administration

Lyndon B. Johnson Space Center

Houston, Texas 77058

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APPROVAL AUTHORITY

________________________________ 

Raymond G. Heineman

Chief, Aircraft Operations Division

original signed by:
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CHANGE RECORD/LIST OF EFFECTIVE PAGES

Doc.

Version Date Process Owner/Ext. Description

Basic Nov 2014 D. McMahon/49698 Basic issue.

Rev A Jan 2016 D. McMahon/49698 Clarify requirements pertaining to floor 

rails, rollers, lock pins, and load limits 

for customers designing shipping pallets 

that will interface with the aircraft.

Rev B Sep 2018 D. McMahon/49698 Modify figures and update text to reflect 

changes to Drawing 4000003, including

information on cargo floor modification, 

MightyGRIP cargo pallet, and MiniGRIP 

cargo adapter; and add Appendix B, 

Airlift Planning Checklist.

Rev C May 2023 E. Prado/34902 Text and tables added to include the 

following: addition of dynamic coupling 

requirements (Section 6.9.5); loader tip 

over and wind analysis (Section 7.3); 

winch capacity (Section 6.2); customer 

payload mass properties form 

(Section 4.0); electrical loads 

clarification questions (Appendix B); 

addition of Airlift Process section 

(Section 11.1); load case modifications 

(Section 6.8) and CLT 1G load case text 

addition (Section 9 and 9.1.1); Batteries 

moved to new section (Section 7.5.12); 

addition of Repeat Airlift section 

(Section 7.8); and addition of 

Uninterruptible Power Supply section 

(Section 7.5.13). Numerous minor 

updates to formatting and language.

Page No. Doc. Version Page No. Doc. Version

Cover.....................................................Rev C A-1 thru A-4........................................ Rev C

i thru viii................................................Rev C B-1 thru B-6 ........................................ Rev C

1 thru 54 ................................................Rev C
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TABLE OF CONTENTS

Section Page

1.0 PURPOSE....................................................................................................................... 1

2.0 SCOPE ............................................................................................................................ 1

3.0 RECORDS...................................................................................................................... 1

4.0 REFERENCES............................................................................................................... 1

5.0 INTRODUCTION.......................................................................................................... 3

6.0 AIRCRAFT DESCRIPTION........................................................................................ 8

6.1 GENERAL....................................................................................................................... 8

6.2 CARGO PROVISIONS................................................................................................. 10

6.3 ELECTRICAL SYSTEM PROVISIONS...................................................................... 10

6.4 CARGO BAY DIMENSIONS ...................................................................................... 13

6.5 AIRCRAFT CENTER OF GRAVITY.......................................................................... 13

6.6 FLOOR RAILS, ROLLERS, AND LOCK PINS.......................................................... 15

6.7 CARGO FLOOR LOAD LIMITS................................................................................. 18

6.8 CARGO DESIGN LOAD FACTORS........................................................................... 20

6.9 ENVIRONMENTAL CONDITIONS ........................................................................... 21

6.9.1 Temperature ................................................................................................................... 21

6.9.2 Pressure.......................................................................................................................... 21

6.9.3 Acoustic Sound Pressure Level ..................................................................................... 22

6.9.4 Random Vibration.......................................................................................................... 22

6.9.5 Dynamic Analysis and Ground Vibration Testing......................................................... 26

7.0 CARGO REQUIREMENTS....................................................................................... 27

7.1 SAFETY CRITICAL ITEMS........................................................................................ 27

7.2 CARGO DESIGN FACTORS OF SAFETY................................................................. 27

7.3 STRESS REPORTS....................................................................................................... 28

7.4 CARGO MASS PROPERTIES..................................................................................... 28

7.5 CARGO DESIGN GUIDELINES................................................................................. 28

7.5.1 Cargo Clearance Limit................................................................................................... 29

7.5.2 Loads.............................................................................................................................. 29

7.5.3 48-Foot Cargo Pallet Interface....................................................................................... 29

7.5.4 MightyGRIP Cargo Pallet Interface............................................................................... 29

7.5.5 Aircraft Floor Roller and Lock Pin Interface................................................................. 30

7.5.6 Materials ........................................................................................................................ 30

7.5.7 Weld Design................................................................................................................... 31

7.5.8 Environment................................................................................................................... 33

7.5.9 Pressure Systems and Sealed Containers....................................................................... 33

7.5.10 Hardware and Equipment .............................................................................................. 33

7.5.11 Flame Retardant Materials............................................................................................. 33

7.5.12 Batteries......................................................................................................................... 33

7.5.13 Uninterruptible Power Supplies..................................................................................... 35

7.6 HAZARDOUS MATERIALS....................................................................................... 35

7.7 NASA AIRWORTHINESS REVIEW .......................................................................... 36
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Section Page

7.8 REPEAT AIRLIFTS...................................................................................................... 37

7.8.1 Payload Questionnaire Form.......................................................................................... 37

7.8.2 Quality Documentation.................................................................................................. 37

7.8.3 Recurring Inspection Plan.............................................................................................. 37

8.0 SUPPORT EQUIPMENT ........................................................................................... 37

8.1 PALLETS ...................................................................................................................... 37

8.1.1 48-Foot Cargo Pallet...................................................................................................... 37

8.1.2 8-Foot Cargo Pallet........................................................................................................ 40

8.1.3 MightyGRIP Cargo Pallet.............................................................................................. 41

8.2 CARGO RESTRAINT HARDWARE .......................................................................... 42

8.3 ADAPTERS................................................................................................................... 43

9.0 CARGO LOADERS .................................................................................................... 44

9.1 CARGO LIFT TRAILER .............................................................................................. 45

9.1.1 Additional CLT Considerations..................................................................................... 47

9.2 RESCUE LOADER....................................................................................................... 48

10.0 FLIGHT COORDINATION....................................................................................... 50

10.1 AIRCRAFT SUPPORT ................................................................................................. 50

10.2 AIRFIELD CONSIDERATIONS.................................................................................. 51

10.3 EN ROUTE STOPS....................................................................................................... 52

10.4 SPECIAL PAYLOAD REQUIREMENTS ................................................................... 52

11.0 AIRLIFT PROCESS, ROLES, AND RESPONSIBILITIES................................... 52

11.1 THE AIRLIFT PROCESS............................................................................................. 52

11.2 NASA RESPONSIBILITIES......................................................................................... 53

11.2.1 Flight Crew .................................................................................................................... 53

11.2.2 Ground Crew.................................................................................................................. 53

11.3 CUSTOMER RESPONSIBILITIES.............................................................................. 53

11.3.1 Customer Flight Support Personnel............................................................................... 54

LIST OF APPENDICES

Appendix Page

A ACRONYMS AND ABBREVIATIONS.................................................................. A-1

B AIRLIFT PLANNING CHECKLIST...................................................................... B-1

LIST OF FIGURES

Figure Page

1 Super Guppy Transport........................................................................................................3

2 Loading Cargo Using a Pallet..............................................................................................4

3 Loader in Position to Load Cargo........................................................................................5

4 Wide Cargo Elevated to Fit Inside the Cargo Bay...............................................................6

5 V-22 Osprey Prepared for Loading......................................................................................7

6 Loaded V-22 Osprey............................................................................................................7
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Figure Page

7 Aircraft Dimensions.............................................................................................................9

8 115 VAC 60 Hz Power Strip Located in Cargo Bay .........................................................11

9 208 VAC Power Connector in Cargo Bay.........................................................................11

10 15A 115 VAC 60 Hz Outlets.............................................................................................12

11 25A 28 VDC Outlet ...........................................................................................................12

12 Pressure Bulkhead Pass-Through ......................................................................................13

13 Cargo Bay Dimensions......................................................................................................14

14 Typical Cargo Bay Cross Section and Lock Pin Locations...............................................16

15 Lock Pin and Floor Rail Load Limits,................................................................................17

16 Floor Beam Shear Limits at FS 553 and FS 655 ...............................................................18

17 Cargo Floor Zones .............................................................................................................19

18 Acoustic Sound Pressure Level .........................................................................................22

19 Vibration Data – Longitudinal (x) .....................................................................................23

20 Vibration Data – Lateral (y)...............................................................................................24

21 Vibration Data – Vertical (z) .............................................................................................25

22 48-Foot Cargo Pallet..........................................................................................................39

23 8-Foot Cargo Pallet............................................................................................................40

24 MightyGRIP Cargo Pallet..................................................................................................41

25 Adapter Weldment Assembly............................................................................................43

26 MiniGRIP Cargo Adapter Installed on 48-Foot Cargo Pallet............................................44

27 Cargo Lift Trailer...............................................................................................................47

28 Maximum Observed Deflection of CLT Deck Under Load ..............................................47

29 Rescue Loader....................................................................................................................49

30 Rescue Loader with Cargo.................................................................................................50

LIST OF TABLES

Table Page

1 Aircraft Specifications.........................................................................................................8

2 Cargo Load Limits for FS 553 and FS 655 Floor Beams..................................................18

3 Cargo Load Limits for All Floor Beams Except FS 553 and FS 655................................19

4 Load Factors for Cargo Designe.........................................................................................20

5 Absolute Atmospheric Pressure.........................................................................................21

6 Emergency Climb and Descent Rates................................................................................21

7 Mode List for Empty Super Guppy ...................................................................................26

8 Permissible Stresses for Welds..........................................................................................32

9 Airworthiness Review Requirements Matrix.....................................................................36

10 48-Foot Cargo Pallet Specifications..................................................................................38

11 8-Foot Cargo Pallet Specifications ....................................................................................40

12 MightyGRIP Cargo Pallet Specifications..........................................................................42

13 CLT and Rescue Loader Mass Properties..........................................................................45

14 Cargo Lift Trailer Specifications.......................................................................................46

15 Rescue Loader Specifications............................................................................................49
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1.0 PURPOSE

This document provides the prospective Super Guppy Transport (SGT) transportation system 

customer with information needed to accomplish the following:

• Determine if the SGT is suitable for the customer’s airlift requirements.

• Understand the SGT airlift process and logistical requirements.

• Understand the roles and responsibilities involved in the airlift process.

For more information, please contact the National Aeronautics and Space Administration 

(NASA) Johnson Space Center (JSC) Aircraft Operations Division (AOD) SGT Program 

Manager listed on the following Web page:

https://www.nasa.gov/specials/jsc-aircraft-ops/guppy.html#contact

2.0 SCOPE

This document applies to all users, potential users, and missions using the NASA JSC SGT

aircraft.

Reference the AOD EDMS (Electronic Document Management System) Library to verify the 

latest version of this document.

3.0 RECORDS

No records are generated by this document.

4.0 REFERENCES

NOTE

Contact NASA Engineering for access to all NASA AOD 

documents.

Aero Spacelines report No. 700-3

Aero Spacelines report No. 700-9

AOD 40-0000088, ATA Report No. 69274, “TO A-05 Ground Vibration Test of the Super 

Guppy Transport with Orion Crew Module Transport Simulator”

AOD 4094013, Super Guppy Boundary Condition Stiffness

AOD 4094015, 8-Foot Pallet Tie-Down Load Allowable

AOD 4094016, Guppy Ground and Flight Temperature Data

AOD 4094019, Analysis of Lateral Loading Limits on Super Guppy Payload Retention Rails

AOD 4094022, Super Guppy Strain Flight Test and Floor Beam Analysis Updates

AOD 8594001, Preparation of Stress Analysis Reports

AOD 8594002, Design and Analysis Handbook, Aircraft Operations Division
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AOD Form 424, Super Guppy Payload Mass Properties Form

AOD Form 429, Super Guppy Payload Questionnaire Form

ASL 101-1, Pallet, Rail, and Pallet Lock Analysis

American Society for Testing and Materials (ASTM) A500, Standard Specification for ColdFormed Welded and Seamless Carbon Steel Structural Tubing in Rounds and Shapes

ASTM A572, Standard Specification for High-Strength Low-Alloy Columbium-Vanadium 

Structural Steel

ASTM A673, Standard Specification for Sampling Procedure for Impact Testing of Structural 

Steel

D98003.001, Super Guppy Interior Vibration & Acoustics Characterization

Drawing (DWG) 40-0000057, Lift Plan, MightyGRIP Assembly

DWG 40-0000061, Interface Drawing, MightyGRIP

DWG 4000003, Super Guppy Dimensional Layouts

DWG 4091537, Adapter Weldment Assy

DWG 4091540, 8-Ft Pallet Assembly, Cargo, Super Guppy

DWG 4091547, Lift Plan, 36-Foot Pallet Assembly

DWG 4091548, Lift Plan, 12-Foot Pallet Assembly

Federal Aviation Regulation (FAR) 25.853, Compartment interiors

JSC-20793 Crewed Space Vehicle Battery Safety Requirements

JSC-63322 Packaging Requirements for Launch, On-Orbit Storage and Disposal of Batteries

JSC Procedural Requirement (JPR) 1710.13, Design, Inspection, and Certification of GroundBased Pressure Vessels and Pressurized Systems

NASA Procedural Requirement (NPR) 6200.1, NASA Transportation and General Traffic 

Management

National Fire Protection Association (NFPA) 701, Standard Methods of Fire Tests for Flame 

Propagation of Textiles and Films

National Space Transportation System (NSTS) 1700.7, Safety Policy and Requirements for 

Payloads Using the Space Transportation System

NSTS 1700.7 (ISS Addendum), Safety Policy and Requirements for Payloads Using the 

International Space Station

PRC-0001, Process Specification for the Manual Arc Welding of Aluminum Alloy Hardware1

1

See https://www.nasa.gov/specials/jsc-aircraft-ops/guppy.html#contact
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PRC-0005, Process Specification for the Manual Arc Welding of Carbon Steel and Nickel Alloy 

Hardware

Standard Operating Procedure (SOP)-009.98, Preparation of an Operation & Configuration 

Control Plan (OCCP) for “Category B” Pressure Vessels/Systems (PV/S)

5.0 INTRODUCTION

The SGT (see Figure 1) is part of a transportation system primarily intended for payloads that 

either are too large for shipment by conventional means or require special handling, such as 

aerospace hardware.

Figure 1. Super Guppy Transport

In the past, the SGT has been used to transport rocket segments, space station components, 

aircraft, and test articles. The aircraft is adaptable to accommodate different payloads; however, 

payloads must be designed to integrate with the SGT, either directly or through the use of a 

SGT-specific pallet (see Figure 2).

Typically, cargo is secured to a pallet and then loaded into the aircraft (see Figure 3). The tops 

of the pallets are flat and have threaded holes used to secure the payload. Normally, NASAprovided tie-down rings, cargo chains, and chain adjustment turnbuckles are used; however, 

bolts may be substituted for the rings in the event that a payload or its supporting structure can be 

bolted directly to the pallet. While several pallets are available for customer use (refer to 

Section 8.1, Pallets), a purpose-built fixture can be used in lieu of a pallet.
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Figure 2. Loading Cargo Using a Pallet

The loader (see Figure 3) is a piece of ground support equipment designed to carry the payload 

to the SGT, raise the payload/pallet even with the cargo bay floor, and permit the loading or 

unloading of the payload. Rollers on both the loader and the SGT cargo bay floor support the 

weight of the payload, as it is moved from the loader into the aircraft using an aircraft-mounted 

winch and tow bar. Once the payload is inside the SGT, lock pins on the aircraft floor 

hydraulically engage holes on the sides of the pallet, thus locking the payload to the aircraft.

Payloads must be able to withstand altitude pressure changes or have adequate venting since the 

cargo bay is neither pressurized nor environmentally controlled. If the payload requires

environmental control, the customer may elect to provide an Environmental Control System (ECS) 

to control the payload’s temperature or humidity; the SGT can provide electrical power to the 

cargo bay for operation of the ECS. ECS control and payload monitoring can be accomplished by 

either wired or wireless means to a recording system (e.g., laptop) in the cockpit.
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Figure 3. Loader in Position to Load Cargo

Because of the unique cross section of the SGT cargo bay, many payloads are too wide to fit 

directly on top of the pallet. Payloads are frequently required to be elevated, so that the widest 

part of the payload fits within the widest part of the cargo bay (see Figure 4). Structures that 

elevate the payload are typically developed and provided by the customer, and are “sized” to 

minimize weight while maximizing the strength and stiffness needed to support the payload 

during normal flight and emergency landing conditions.

NOTE

• Clearance must be accurately defined in the planning 

stage to prevent issues during cargo loading (refer to 

Section 7.5, Cargo Design Guidelines).

• Payloads may also need to be elevated for other reasons 

(e.g., to facilitate chain tie-downs).
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Figure 4. Wide Cargo Elevated to Fit Inside the Cargo Bay

Refer to the following case study for a discussion on payload elevation.

Payload Case Study

The V-22 Osprey is angled in such a way as to raise the nose and lower the tail (see Figure 5). 

The Osprey is also secured with chains and supported by a structure that distributes the weight of 

the aircraft along the length of the pallet.

This orientation raises the aircraft vertically to be in the widest part of the SGT and ensures the 

upper and lower tips of the two vertical stabilizers clear the interior (see Figure 6). The elevated 

position of the aircraft allows the weight to be distributed from the main landing gear to a large 

portion of the pallet.
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Figure 5. V-22 Osprey Prepared for Loading

Figure 6. Loaded V-22 Osprey
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No two payloads or customer requirements are alike; therefore, AOD works with each customer 

throughout the payload integration process to ensure a safe airlift. Key payload planning 

considerations are as follows:

• Will the integrated payload fit inside the SGT?

• Can the weight of the integrated payload be distributed on the cargo bay roller system within 

the aircraft floor load limits?

• Can the integrated payload be restrained for flight and crash conditions?

• Can the payload be installed and meet the longitudinal and vertical Center of Gravity (CG) 

requirements?

6.0 AIRCRAFT DESCRIPTION

6.1 GENERAL

The SGT is a modified Boeing C-97/B377, designated 377-SGT-F. It is powered by four 

Allison 501 D22 turboprop engines2 and can accommodate a maximum Allowable Cabin 

Load (ACL) of 48,000 pounds (lbs), including the payload, cargo pallet(s), payload-specific 

aircraft equipment, and/or payload adapters.3 For aircraft specifications and performance, refer 

to Table 1 and see Figure 7.

Table 1. Aircraft Specifications

Item Value

Maximum Ramp Weight 171,000 lbs

Maximum Takeoff Weight 170,000 lbs

Minimum In-flight Weight 105,000 lbs

Maximum Landing Weight 160,000 lbs

Empty Weight 101,000 lbs

Maximum Zero Fuel Weight 154,000 lbs

Total Fuel Capacity 6,580 U.S. Gallons (USG)

Cargo Bay Dimensions Refer to Section 6.4, Cargo Bay Dimensions

Cruise Speed 240 knots

Block Hour Speed 200 knots

Maximum Range 800 miles

ACL 48,000 lbs3

2

The Allison 501-D is the commercial version of the T56 engine used in aircraft such as the C-130H and P-3.

3

48,000 lbs based on optimal flight conditions. The maximum payload may be reduced dependent on the flight path (e.g., distance 

between airports along flight path for refueling) and airfield conditions (e.g., airfield temperature and altitude). For example, for 

an SGT flight from the Kennedy Space Center to the east coast during the winter, 48,000 lbs may be achievable. However, for an

SGT flight from the Kennedy Space Center to the west coast during the summer, 36,000 lbs may be more likely.
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Figure 7. Aircraft Dimensions4

4 See DWG 400003, Super Guppy Dimensional Layouts.
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6.2 CARGO PROVISIONS

The SGT has the following provisions for cargo:

NOTE

The aircraft cargo bay is not pressurized or environmentally 

controlled, possibly placing altitude limitations on sensitive 

cargo (refer to Section 6.9 Environmental Conditions).

• Swing Nose – Payloads are installed into the aircraft through the swing nose. The swing 

nose, hinged at one location, is rotated 100 degrees by an electrically powered outrigger. The 

cargo floor is approximately 11 feet (ft) AGL (Above Ground Level); transloading cargo is 

accomplished by raising the loader platform to the aircraft cargo deck level.

• Lighting – The cargo area is illuminated by five flood lamps equally spaced on each side of 

the aircraft. Cargo bay dimensions are detailed in Section 6.4, Cargo Bay Dimensions.

• Floor Rails/Rollers – Dual parallel floor rails with rollers and guides are installed from 

Fuselage Station (FS) 210 to FS 1080. Rollers without rails continue from FS 1080 to 

FS 1160 on the cargo floor and are used only for the transloading of cargo. During loading/

unloading operations, the loader rollers are aligned with the aircraft rails.

• Winch – An electrically powered 15,000 inch-pounds (in-lbs) capacity winch is installed in 

the aircraft, providing up to 4,300 lbs of force to move cargo. The winch cable, routed around 

a series of fairleads, forms a closed loop that permits pulling/pushing of cargo in/out of the 

aircraft.

• Lock Pins – Forty-four (44) locking pins are installed to secure the pallet(s) or payload 

fixture to the aircraft. The locking pins are hydraulically powered into mating holes on the 

sides of the pallet(s).

6.3 ELECTRICAL SYSTEM PROVISIONS

The cargo bay has two 15 amp (A) 115 Volts Alternating Current (VAC) 60 Hertz (Hz) circuits 

available via two standard power strips (see Figure 8). If the customer payload requires 

laboratory grade power, (which may occur when instrumentation is being utilized), additional 

filtering equipment and an uninterruptable power source (UPS) may need to be provided by the 

customer. During transitions from ground power to aircraft power and vice versa, there may be 

momentary disruptions in power provided through the aircraft circuits.
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Figure 8. 115 VAC 60 Hz Power Strip Located in Cargo Bay

Additionally, there are two separate 80A sources of 208 VAC, 3 phase, 400 Hz power available 

to the payload (see Figure 9). The aircraft-side connector for this power source is a Part Number 

(P/N) APR10426 receptacle and P/N APJ10487 mating plug.

Figure 9. 208 VAC Power Connector in Cargo Bay

The cockpit area has two standard (household) 15A 115 VAC 60 Hz outlets available for laptops 

or other test/monitoring equipment (see Figure 10). A white covered outlet is located on the left 

wall forward of the pilot’s seat. A silver covered outlet is located on the back wall on the lower 

aft corner of the Flight Engineer (FE) panel. Up to 10A of 28 Volts Direct Current (VDC) power 

is also available.
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Figure 10. 15A 115 VAC 60 Hz Outlets

A single 25A 28 VDC outlet is also located in the forward lower unpressurized section of the 

aircraft (see Figure11). If requested, it can be made available to the cargo bay using an extension 

cable. The mating connector for this outlet is Hubbell P/N HBL7545C.

Figure 11. 25A 28 VDC Outlet

Electrical cables for monitoring and control can be routed from the flight deck to the cargo bay 

through a 2.063-inch diameter pass-through in the pressure bulkhead (see Figure 12).
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Figure 12. Pressure Bulkhead Pass-Through

6.4 CARGO BAY DIMENSIONS

The cargo bay consists of a constant cross section as well as a tapered cross section. The cargo 

bay has a constant cross section that is 368 inches long starting at FS 300 (see Figure 13). 

FS 300 is known as the “fuselage parting line,” at which the hinged nose of the fuselage opens to 

allow loading of the cargo bay. The tapered cross section begins at FS 668 and continues to 

taper moving aft.

To prevent physical interference with the SGT fuselage, a 6-inch minimum clearance envelope 

exists (see Figure 13 and Figure 14) for both static and dynamic conditions; however, NASA’s 

preference is to maintain a 12-inch clearance envelope to minimize detailed payload deflection 

analysis requirements.5,6

6.5 AIRCRAFT CENTER OF GRAVITY

The CG location for the entire aircraft, including payload, must be within the CG range (see 

Figure 13). The longitudinal location of the payload CG in the aircraft can be adjusted by rolling 

the payload forward and aft in 1-foot increments and then locking the payload in position using 

the pallet lock pins (refer to Section 6.6, Floor Rails, Rollers, and Lock Pins). The lateral CG of 

the payload shall be located as close as possible to the centerline of the cargo bay.

NASA loadmasters will calculate the longitudinal location of the payload in the aircraft based on 

the payload weight and CG data provided by the customer in AOD Form 424, Super Guppy 

Payload Mass Properties Form. This calculation, known as the Form F, takes into account not 

only the payload weight but other aircraft variables (e.g., fuel, support equipment, and number of 

crewmembers).

It is helpful if the customer can provide NASA with payload weight and CG estimates as early as 

possible so that NASA can provide a rough estimate of the payload longitudinal location in the 

aircraft for clearance calculations. The longitudinal location can be fine-tuned as more accurate 

payload weight and CG data is obtained.

5 A 3-D computer model of the payload bay is available upon request.

6 The fuselage can deflect in certain emergency flight conditions producing an estimated 6-inch maximum fuselage deflection at

specific fuselage locations. This fuselage deflection must be considered with payloads approaching the 6-inch clearance limit.
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Figure 13. Cargo Bay Dimensions7

7 See DWG 4000003.
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6.6 FLOOR RAILS, ROLLERS, AND LOCK PINS

Cargo interfaces with the SGT via dual parallel floor rails, rollers, and lock pins (see Figure 14). 

The floor rails and rollers ease cargo loading and unloading. The hydraulically activated lock 

pins retract into the floor rails during cargo loading and extend to lock the payload when the 

cargo is properly positioned. Cargo is restrained by the rails, rollers, and lock pins in the 

following manner:

• Longitudinal (x) Direction – Lock pins in shear.

• Lateral (y) Direction – Side contact with floor rails.

• Vertical (z) Direction – Contact with rollers for down loads; lock pins in shear for up loads.

The lock pins and floor rails shown in Figure 14, Detail A, are limited to the ultimate loads 

shown in Figure 15.
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Figure 14. Typical Cargo Bay Cross Section and Lock Pin Locations8

8 See DWG 4000003.
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Figure 15. Lock Pin and Floor Rail Load Limits9,10

9 See DWG 4000003.

10Refer to AOD 4094019, Analysis of Lateral Loading Limits on Super Guppy Payload Retention Rails; and ASL 101-1, Pallet, 

Rail, and Pallet Lock Analysis.
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6.7 CARGO FLOOR LOAD LIMITS

The total cargo weight, including the payload, cargo pallet(s), payload-specific aircraft 

equipment, and/or payload adapters, is limited to 48,000 lbs. The cargo weight applied to each 

floor beam shall not exceed certain loads (refer to Table 2 and Table 3). The FS 553 Floor Beam 

and FS 655 Floor Beam are significantly stiffer than the other floor beams, resulting in higher 

local stresses11 (see Figure 16).

See Figure 17 for cargo floor zones. NOTE

The shear loads, shown in Table 2 and Table 3, are the total 

loads applied to any SGT floor beam via the roller rails, 

and include the weight of any pallets, if used. The shear 

limits, specifically for the large floor beams at FS 553 and 

FS 655, are shown in Table 2, and the load application is 

shown in Figure 16. The limits for the remaining floor 

beams are shown in Table 3.

Table 2. Cargo Load Limits for FS 553 and FS 655 Floor Beams12

Zone 1G Shear Loadmax

(per side of each floor beam)

Flight Shear Loadmax

(per side of each floor beam)

Crash Shear Loadmax

(per side of each floor beam)

FS 553 +2,487 lbsdown +6,400 lbsdown +11,192 lbsdown

FS 655 +2,849 lbsdown +7,333 lbsdown +12,823 lbsdown

Figure 16. Floor Beam Shear Limits at FS 553 and FS 65513

11These higher local stresses were not taken into account in initial structural substantiations of the SGT. To accommodate heavier 

payloads, the floor has been modified to allow the load to be more evenly distributed across the floor. Refer to CCPD 

(Configuration Control Panel Directive) 40.06.0099, Super Guppy Floor Load Modification.

12Refer to Section 6.8, Cargo Design Load Factors.

13Refer AOD 4094022, Super Guppy Strain Flight Test and Floor Beam Analysis Updates.
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NOTE

The shear loads shown in Table 3 are applied in the same 

manner as shown in Figure 16. The running load, in the 

last column of Table 3, is applied linearly (fore/aft) along 

each roller rail. The SGT cargo bay floor zones are shown 

in Figure 17.

Table 3. Cargo Load Limits for All Floor Beams Except FS 553 and FS 65514

Zone

1G Shear Loadmax

(per side of 

each floor beam)

Flight Shear Loadmax

(per side of 

each floor beam)

Crash Shear Loadmax

(per side of 

each floor beam)

Approximate 1G 

Running Loadmax

(average for any

16-inch length)

A +1,000 lbsdown +3,000 lbsdown +4,500 lbsdown

+62.5 pounds per inch 

(lbs/in) per floor raildown

B +480 lbsdown +1,440 lbsdown +2,160 lbsdown +30 lbs/in per 

floor raildown

C +400 lbsdown +1,200 lbsdown +1,800 lbsdown +25 lbs/in per 

floor raildown

Figure 17. Cargo Floor Zones15

14Refer to Section 6.8 Cargo Design Load Factors.

15See DWG 4000003.
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6.8 CARGO DESIGN LOAD FACTORS

Cargo shall be designed for two types of loading conditions:

• Flight Load Factors16 17 – Flight load factors are applied simultaneously in three directions.

• Crash Load Factors – Crash load factors are applied independently.

All cargo safety critical18 items shall be analyzed in accordance with (IAW) the load factors 

listed in Table 4.

Table 4. Load Factors for Cargo Designe

Load Casea Forward/Aft (G) Lateral (G) Vertical (G)b

Flight/Landing 1c 1 Forward 0 2.5 Down

Flight/Landing 2c 1 Forward 0 1 Up

Flight/Landing 3c 1 Aft 0 2.5 Down

Flight/Landing 4c 1 Aft 0 1 Up 

Flight/Landing 5c 0.5 Forward 1.0 Left 1.6 Down

Flight/Landing 6c 0.5 Forward 1.0 Right 1.6 Down

Flight/Landing 7c 0.5 Aft 1.0 Right 1.6 Down

Flight/Landing 8c 0.5 Aft 1.0 Left 1.6 Down

Crash 1d 3 Forward 0 0

Crash 2d 1.5 Aft 0 0

Crash 3d 0 1.5 Left 0

Crash 4d 0 1.5 Right 0

Crash 5d 0 0 4.5 Down

Crash 6d 0 0 2 Up

a Load factors act at the CG of the cargo.

b Vertical load factors include 1G added for gravity.

c Flight loads occur simultaneously in the three directions shown.

d Crash loads occur independently in the three directions shown.

e Directions relative to aircraft

16Also referred to as “limit” loads.

17Flight/Landing Cases 5-8 were added after the completion of Artemis I CSM airlift. Accelerometers installed on the Super 

Guppy cargo rails indicated a lateral component of loading while landing and these load cases represent the factors that are 

bounding condition.

18Refer to Section 7.1, Cargo Requirements, for the definition of “safety critical.”
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6.9 ENVIRONMENTAL CONDITIONS

Environmental factors that could affect the integrity of the cargo during transport 

(i.e., temperature, pressure, acoustic, and vibration conditions) should be considered in the cargo 

design process and shall be addressed in the cargo structural analysis report (refer to Section 7.3, 

Stress Reports).

6.9.1 Temperature

Unless otherwise specified, 0° Fahrenheit (F) [-18° Celsius (C)] and 150°F (66°C) should be used 

as the temperature extremes for payload design. Although the fuselage provides some insulation, 

air temperature within the cargo area will eventually reach the exterior temperature at flight 

altitude (cold extreme). In addition to flight conditions, the temperature during ground 

operations shall be considered. For example, while on the ground during hot sunny days, air 

temperature in the cargo bay can increase greatly due to the lack of air circulation. Air 

temperatures as high as 150°F (66°C) have been recorded in the cargo bay during +100°F (38°C)

sunny days.19 The effects of temperature change on cargo material properties and the induced 

thermal stress at constrained structural members shall be taken into account during design.

6.9.2 Pressure

Standard atmosphere pressure data shall be used in design calculations based on the maximum 

altitude planned for the mission (typically 18,000 ft). Sample data points are shown in Table 5.

Table 5. Absolute Atmospheric Pressure

Altitude

(ft)

Pressure

(psia)

Sea Level 14.70

5,000 12.23

10,000 10.11

15,000 8.29

20,000 6.75

The payload structure shall be designed to accommodate the positive or negative pressures based 

on these climb/descent rates. If the cargo is sealed, the structure shall be analyzed based on the 

altitude induced pressure loads. If the cargo is vented, vents must be sized to accommodate the 

emergency climb and descent rates listed in Table 6.

Stresses due to pressure loading shall be accounted for in the structural analysis and combined 

with the flight loads; pressure loads do not need to be combined with the crash loads.

Table 6. Emergency Climb and Descent Rates

Condition Climb/Descent Rate

(ft/min)

Pressure Rate of Change

(psi/min)

Climb 1,500 0.755

Descent 3,000 1.55

19 Refer to AOD 4094016, Guppy Ground and Flight Temperature Data.
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6.9.3 Acoustic Sound Pressure Level

An example of acoustic flight test data is shown in Figure 18. This data was recorded in the SGT 

payload bay and is provided for payloads that may be sensitive to acoustic sound pressure levels.20

1/3 OCTAVE PLOT and TABULAR DATA

SUPER GUPPY – INTERIOR VIBRATION & ACOUSTICS

MODEL:

SHIP NO: N941NA

TWR:

TEST NO:

TEST SITE: HOUSTON

TEST ENG: B. HOARE

MEASURAND: (Ch 1) DATE PROCESSED: 27-Jan-1998 10:02:19

DESCRIPTION: MIC – STA 414, AIRCRAFT CL, 95° ABOVE FLOOR

NE830

AVG TIME = 150.0 sec

AVG OASPL = 118.9

MAX OASPL = 125.5

TEST DATE: 1/21/98

TOD: 10:29:00

FLIGHT:

FLT CARD:

DATA TAPE: SV 3793

RECORDER: SONY SIR-1000

TEST CONDITION: TAKEOFF AND CLIMB TO 2000FT DPR #: 98-002

1/3 OB

Frequency 

(Hz)

Average

SPL

(dB)

Maximum

SPL

(dB)

31.5 90.9 98.9

40.0 88.1 97.5

50.0 94.5 100.3

63.0 117.6 124.4

80.0 111.5 118.3

100.0 93.3 100.2

125.0 107.0 114.4

160.0 102.2 109.7

200.0 102.7 109.7

250.0 97.2 103.5

315.0 94.5 101.8

400.0 92.0 99.7

500.0 90.7 98.5

630.0 89.3 96.1

800.0 88.2 96.3

1000.0 84.8 92.7

1250.0 86.5 94.6

1600.0 82.2 90.6

2000.0 79.8 87.9

2500.0 79.6 86.0

Figure 18. Acoustic Sound Pressure Level

6.9.4 Random Vibration

Example longitudinal (x), lateral (y), and vertical (z), vibration flight test data are shown in 

Figure 19, Figure 20, and Figure 21. The test data was obtained using a simulated payload 

comprised of three pallets with a 5,000 lb ballast weight installed on each pallet for a total of 

15,000 lbs.

NOTE

Figure 19, Figure 20, and Figure 21 are presented for 

example purposes only. Vibration-sensitive payloads may 

require flight testing with a test setup more representative 

of the payload installation.

20 Refer to D98003.001, Super Guppy Interior Vibration & Acoustics Characterization.

Average SPL

• • • Maximum SPL
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POWER SPECTRAL DENSITY PLOT

SUPER GUPPY – INTERIOR VIBRATION & ACOUSTICS

MODEL:

SHIP NO: N941NA

TWR:

TEST NO:

TEST SITE: HOUSTON

TEST ENG: B. HOARE

DATE PROCESSED: 13-Feb-1998 09:26:31 SAMPLE PLATE = 2049 s/s

FILTER BW = 2 Hz

AVG TIME = 60.96 sec

AVE/OVERLAP = 122 / 0

WINDOW = HANN

FLT MAX RMS = 0.137

TEST DATE: 1/21/98

TOD: 10:17:00

FLIGHT:

FLT CARD:

DATA TAPE: SV 3793

RECORDER: SIR-1000

TEST CONDITION: FULL FLIGHT PROFILE DPR #: 98-003

PARAM # (Ch 9) DESCRIPTION: STA 550, LHS CARGO RAIL – LONG (G)

Figure 19. Vibration Data – Longitudinal (x)
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POWER SPECTRAL DENSITY PLOT

SUPER GUPPY – INTERIOR VIBRATION & ACOUSTICS

MODEL:

SHIP NO: N941NA

TWR:

TEST NO:

TEST SITE: HOUSTON

TEST ENG: B. HOARE

DATE PROCESSED: 13-Feb-1998 09:25:02 SAMPLE PLATE = 2049 s/s

FILTER BW = 2 Hz

AVG TIME = 60.96 sec

AVE/OVERLAP = 122 / 0

WINDOW = HANN

FLT MAX RMS = 0.28

TEST DATE: 1/21/98

TOD: 10:17:00

FLIGHT:

FLT CARD:

DATA TAPE: SV 3793

RECORDER: SIR-1000

TEST CONDITION: FULL FLIGHT PROFILE DPR #: 98-003

PARAM # (Ch 8) DESCRIPTION: STA 550, LHS CARGO RAIL – LAT (G)

Figure 20. Vibration Data – Lateral (y)
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POWER SPECTRAL DENSITY PLOT

SUPER GUPPY – INTERIOR VIBRATION & ACOUSTICS

MODEL:

SHIP NO: N941NA

TWR:

TEST NO:

TEST SITE: HOUSTON

TEST ENG: B. HOARE

DATE PROCESSED: 13-Feb-1998 09:29:27 SAMPLE PLATE = 2049 s/s

FILTER BW = 2 Hz

AVG TIME = 60.96 sec

AVE/OVERLAP = 122 / 0

WINDOW = HANN

FLT MAX RMS = 0.3131

TEST DATE: 1/21/98

TOD: 10:17:00

FLIGHT:

FLT CARD:

DATA TAPE: SV 3793

RECORDER: SIR-1000

TEST CONDITION: FULL FLIGHT PROFILE DPR #: 98-003

PARAM # (Ch 16) DESCRIPTION: STA 790, LHS CARGO RAIL – VERT (G)

Figure 21. Vibration Data – Vertical (z)
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6.9.5 Dynamic Analysis and Ground Vibration Testing

Dynamic interaction between the aircraft and a payload is payload-specific and may be of 

concern for certain payloads. To provide some information, Ground Vibration Testing (GVT) 

was performed for the Super Guppy with and without a simulated payload. The modes and

resonant frequencies for the empty Super Guppy were identified and are provided in Table 7.

This table and further information are available in report AOD 40-0000088.

Table 7. Mode List for Empty Super Guppy
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Modes that result in floor movement along with low order frequencies (below 20 Hz) are 

typically most relevant for payloads as they are considered structurally significant. Frequencies 

above are considered environmental conditions. Care shall be taken to ensure that dynamic 

coupling will not occur between the payload and the aircraft. Further engineering evaluation and 

approval may be required if the possibility of dynamic coupling or dynamic amplification exists.

General guidance is for the payload resonant frequencies to be one (1) octave away from aircraft 

floor frequencies to prevent coupling. 

In addition to the modes and frequencies provided above, the propellers have a resonant 

frequency of 17 Hz which has been observed in previous GVTs.

For additional historical reports covering GVT, modal data and vibration analysis, refer to Aero 

Spacelines report No. 700-3 and report No. 700-9. Animations of aircraft modes is available 

upon request in FEMAP Neutral File format.

7.0 CARGO REQUIREMENTS

This section specifies the design requirements for cargo transported on board the SGT. The 

guidelines are provided to ensure the safe delivery of the cargo during normal operational 

conditions (limit load condition) as well as the safe egress of the aircrew in the event of an 

emergency landing (crash condition).

NOTE

The AOD Engineering Branch has the final sign-off on the 

airworthiness of the cargo and the cargo restraint method.

7.1 SAFETY CRITICAL ITEMS

This document refers to “safety critical” items. Failure of a safety critical item can result in a 

catastrophic hazard (i.e., critical damage to the aircraft or injury to personnel).

7.2 CARGO DESIGN FACTORS OF SAFETY

All cargo flight safety critical items shall be analyzed IAW the Factors of Safety (FS) in 

AOD 8594002, Design and Analysis Handbook, Aircraft Operations Division, Appendix B.3, 

Cargo Load Factors. The FS are intended to prevent permanent, detrimental deformation under 

limit loads and to prevent structural failure under crash loads. The FS in AOD 8594002, 

Appendix B.3, shall be used to calculate the Margin of Safety (MS) IAW the following equation

[for crash loads, the FS is equal to one (1)]:

MMMM = AAAAAAAAAAAAAAAAAA SSSS SSSS

AAAAAAAAAAAAAA SSSS SSSS × SS SSSS FF FF − 1

All cargo elements shall have a positive MS. The allowable stress is the material yield stress for 

limit loads and ultimate stress for crash loads.
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7.3 STRESS REPORTS

A stress report21 shall be prepared by the customer covering the cargo installation in the aircraft. 

The stress report shall address both in-flight limit loads and crash loads and shall show positive 

margins for all load conditions. The stress report shall, at a minimum, include the following:

• Calculations for flight safety critical cargo and shipping fixture structures including welded 

or bolted joint analysis.

• Calculations for floor loading showing that running loads identified in Section 7.5, Cargo 

Design Guidelines, are not exceeded.

• Calculations for any chain or bolted pallet tie-downs showing that tie-down loads are not 

exceeded.22

• Calculations for rigging lift points.23

• Deflection analysis showing that the minimum 6-inch clearance envelope is not violated.

• Consideration of wind loading that may contribute to tip-over during ground operations (i.e.,

elevated loader operations) if not bounded by past payloads.

• Calculations of stresses and deflection of payload for 1G load case on CLT as detailed in 

Section 9.1.1.

• Payload resonant frequencies and mode shapes as well as consideration of dynamic coupling 

with aircraft resonant frequencies.

Additional clarification or analysis may be requested beyond the listed items for payloads with 

unique considerations. Early engagement with AOD is recommended to determine potential 

consideration.

7.4 CARGO MASS PROPERTIES

Customers shall provide the final as-measured mass properties to the AOD Engineering Branch, 

including the total cargo weight and CG location in all three directions (x, y, z) prior to flight. 

The CG location shall be referenced to lock pin hole #1 in the pallet (see Figure 22). Weight and 

balance calculations for the loaded aircraft will be performed by NASA loadmasters to verify 

payload weight and CG compliance and to determine payload positioning in the aircraft.

The Super Guppy Payload Mass Properties worksheet, AOD Form 424, shall be provided for 

both initial and refined estimates.

7.5 CARGO DESIGN GUIDELINES

The following guidelines shall be used for payload design.

21 Refer to AOD 8594001, Preparation of Stress Analysis Reports, for stress report preparation guidance.

22 Contact NASA AOD Engineering for SGT floor stiffness and chain analysis guidance.

23 Lift points require an FS = 5.
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7.5.1 Cargo Clearance Limit

The minimum cargo “dynamic” clearance to the SGT fuselage shall be 6 inches.24 For cargo

approaching the 6-inch clearance limit, a detailed deflection analysis shall be performed that 

takes into account all combined dynamic deflections for flight load conditions (e.g., cargo 

deflection, shipping fixture deflection, floor deflection).

7.5.2 Loads

A. The maximum running load applied to the floor rollers shall not exceed the values shown 

in Table 2.

25

B. Refer to AOD 8594002, Appendix B.4, for the FS used for MS calculations.

7.5.3 48-Foot Cargo Pallet Interface

A. The 48-foot cargo pallet is comprised of a 36-foot section and a 12-foot section that are 

pinned together. These pallets can be separated and used independently, if required.

B. Loads applied to the pallet surface shall be concentrated within 14 inches of the pallet sides 

(see Figure 22). The load shall be concentrated as much as possible on pallet outer 

longitudinal c-channels.

C. See Figure 22 for the pallet tie-down capability. The loads shown in Figure 22 are the total 

vector sum allowable at the specified tie-down points.

D. Structures interfacing with the pallet shall have a surface flatness of 0.125 inches or less.

E. Refer to AOD 4094013, Super Guppy Boundary Condition Stiffness, for SGT floor 

stiffness and pallet chain tie-down design guidance.

7.5.4 MightyGRIP Cargo Pallet Interface26

A. The MightyGRIP cargo pallet is comprised of twelve 4-foot modular segments that are 

bolted together. The maximum length achievable is 48 ft. Segments may be removed to 

decrease flight weight or separated to create independent pallets, if required.

B. Loads shall be concentrated as much as possible on the outer side rails, as shown in 

DWG 40-0000061. Smaller payloads shall distribute weight across the seat tracks.

C. Refer to DWG 40-0000061 for the pallet tie-down capability. The loads shown are the 

total vector sum allowable at the specified tie-down points.

D. Structures interfacing with the pallet shall have a surface flatness of 0.125 inches or less.

E. Refer to AOD 4094013 for SGT floor stiffness and pallet chain tie-down design guidance.

24 NASA prefers a 12-inch clearance, if possible, to avoid detailed payload deflection calculations.

25 Contact NASA AOD Engineering for SGT floor stiffness and chain analysis guidance.

26 See DWG 40-0000061.
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7.5.5 Aircraft Floor Roller and Lock Pin Interface

Shipping fixtures designed to interface directly with the SGT floor rollers and lock pins (i.e., do 

not use a NASA-supplied pallet) shall meet the applicable design requirements outlined in this 

document in addition to the following:

A. Shall not exceed the SGT floor loads with payload installed (refer to Section 6.7, Cargo 

Floor Load Limits).

B. Shall meet the SGT design load factors with payload installed (refer to Section 6.8, Cargo 

Design Load Factors).

C. Shall have a surface flatness of 0.125 inches or less for the surfaces contacting the SGT 

floor rollers. Additionally, any substantive protrusions (e.g., weld beads, structural 

mismatch) on surfaces that contact the rollers or side rails shall be ground flush to allow for 

smooth translation.

D. Shall have a straightness of 0.125 inches or less over the length of the shipping fixture for 

surfaces contacting the SGT side rails (see Figure 14).

E. Shall have an overall width of 104.5 inches for the surfaces contacting the SGT rollers.

F. Shall be designed to consider differential thermal expansion issues that may affect lock pin 

hole alignment or loads.

G. Shall have provisions to interface with the SGT winch connection, such as the MightyGRIP 

winch clevis described in DWG 40-00000061.

H. Shall have provisions to tie down the shipping fixture to the cargo loader during transport 

to and from the aircraft (refer to Section 9.0, Cargo Loaders).

I. Shall have lift points to lift the shipping fixture and payload onto the loader.

J. Shall contact NASA for guidance on drilling the lock pin hole pattern (see Figure 22 and 

DWG 40-00000061).

K. Shall plan for test fit of shipping fixture in the SGT prior to initial move.

L. Shall provide a gradual lead-in on the forward and aft corners of the fixture.

7.5.6 Materials

A. Impact strength of materials subject to brittle transition at low temperatures shall be tested 

(refer to Section 6.9.1, Temperature).

• ASTM A500, Standard Specification for Cold-Formed Welded and Seamless Carbon Steel 

Structural Tubing in Rounds and Shapes – Charpy V-notch samples shall be required for the 

procured steel lot(s) and shall test ≥15 foot-pounds force (ft-lbf) (full size samples IAW

ASTM A673, Standard Specification for Sampling Procedure for Impact Testing of 

Structural Steel) or equivalent (Table 1 in ASTM A673) at 0°F (-18°C).
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• ASTM A572, Standard Specification for High-Strength Low-Alloy Columbium-Vanadium 

Structural Steel – Charpy V-notch samples shall be required for the procured steel lot(s) and 

shall test ≥15 ft-lbf (full size samples IAW ASTM A673) or equivalent (Table 1 in ASTM 

A673) at 0°F (-18°C).

• ASTM A500 and ASTM A572 welded joints – Charpy V-notch samples shall be required for 

the welded joints and shall test ≥15 ft-lbf (full size samples IAW ASTM A673) or equivalent 

(Table 1 in ASTM A673) at 0°F (-18°C). The V-notch shall be machined in the welded joint. 

Weld samples shall be required for each weld wire lot.

7.5.7 Weld Design

A. Safety critical aluminum welding shall conform to PRC-0001, Process Specification for the 

Manual Arc Welding of Aluminum Alloy Hardware, or industry equivalent.

27

B. Safety critical steel welding shall conform to PRC-0005, Process Specification for the 

Manual Arc Welding of Carbon Steel and Nickel Alloy Hardware, or industry equivalent.

26

C. All weld processes shall include a weld class call-out (e.g., Class A, Class B) on the 

drawing IAW PRC-0001 and PRC-0005, or industry equivalent.

D. Welds shall be designed as to not exceed the permissible stresses shown in Table 8. The 

permissible stresses shown in Table 8 intended to align with standard industry codes [e.g., 

AWS (American Weld Society), AISC (American Institute of Steel Construction)].

E. Weld procedures shall be approved by NASA prior to welding.

F. Welded joints shall be analyzed and presented in the stress report.

27 See http://mmptdpublic.jsc.nasa.gov/prc/prclist.htm.
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Table 8. Permissible Stresses for Welds28

Type of Loading Type of Weld Permissible 

Stressa

Effective 

Factors of 

Safetyd

Tension Butt 0.60Sy

b 1.67yld

Bearing Butt 0.90Sy 1.11yld

Bending Butt 0.60Sy 1.67yld

Simple Compression Butt 0.60Sy 1.67yld

Shear or Partial Joint Penetration (base metal) Butt or Fillet 0.40Sy 1.44yld

Shear or Partial Joint Penetration (weld metal) Butt or Fillet 0.30Sutc 2.50ult

a For lift points, the permissible stress shall be divided by four for material yield strength (Sy) and by five for material 

ultimate tensile strength (Sut). For materials sensitive to residual stresses from welding (e.g., titanium), the 

permissible stresses listed in Table 8 assume that the weldment has been stress-relieved.

b Sy represents the as-welded yield strength of the base metal. For example, the as-welded properties of many 

aluminum alloys have a lower yield strength following welding unless the weldment undergoes a post-weld heat 

treatment.

c Sut represents the ultimate tensile strength of the filler metal.

d The factors of safety are calculated as follows:

Tension, Bending, Simple Compression FF yyyyyyyyyy = 1

0.60 = 1.67

Bearing FF yyyyyyyyyy = 1

0.90 = 1.11

Shear base metalyield FF yyyyyyyyyy = 0.577

0.40 = 1.44

0.577 based on distortion energy theory shear failure criteria.

Shear weld metalultimate FF yyyyyyyyyy = 1

0.30 xx0.75 = 2.50

0.75 is approximate ultimate shear strength of fillet material since SUlt in factor of safety equation is based on 

ultimate tensile strength

Welds shall be designed to not exceed the permissible stresses in Table 8 The permissible 

stresses shown in Table 8 are intended to align with standard industry codes such as the 

American Weld Society (AWS) and the American Institute of Steel Construction (AISC).

For welds, the Margin of Safety is calculated based on the following equation:

MMMMyyyyyyyyyy (uu uu uuuu ffffff 0.30SS cc cc ) = PP PP SSSS SSSS ( TT 8)

CC CC SSSS SSSS − 1

An additional FS (e.g., FS=1.5) is not required in the denominator of the above calculation since 

the permissible stresses listed in Table 8 already include the appropriate safety factor. 

28 Refer to AOD 8594002 for more information.
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7.5.8 Environment 

A. The cargo bay is completely unpressurized and unheated/cooled. Typical cargo bay

temperatures can range from 0°F to 150°F (-18°C to 66°C) depending on the airfield

location and time of year.

B. Differential thermal expansion shall be considered for shipping fixture designs. For

example, the differential thermal expansion for a 288-inch long steel structure interfacing

with the SGT aluminum pallet will be 0.020 inches for every 10°F (-12°C) change in cargo

bay temperature.

7.5.9 Pressure Systems and Sealed Containers

A. Payloads that contain pressure systems or sealed containers shall be evaluated IAW

JPR 1710.13, Design, Inspection, and Certification of Ground-Based Pressure Vessels and

Pressurized Systems.

B. If required, NASA will generate an OCCP with customer design and analysis input IAW

SOP-009.98, Preparation of an Operation & Configuration Control Plan (OCCP) for

“Category B” Pressure Vessels/Systems (PV/S).

C. The maximum descent rate to be used in venting calculations shall be 3,000 ft/min.

7.5.10 Hardware and Equipment 

A. Fasteners shall include a locking feature. Lock nuts are preferred over lock washers.

1. If applicable, limits for reuse of locking hardware shall be considered.

B. Safety critical hardware (i.e., fasteners, lift/tie-down rings) require material certification

paperwork.

7.5.11 Flame Retardant Materials

A. Any materials exposed to possible ignition sources shall be flame retardant IAW

FAR 25.853, Compartment interiors, Appendix F, (a)(i), or equivalent. Refer to

AOD 8594002, Section 2.2, Material Safety, for guidance.

B. Any materials (including, but not limited to shrink wraps) used to cover a payload shall

conform to NFPA 701, Standard Methods of Fire Tests for Flame Propagation of Textiles

and Films, or equivalent.

7.5.12 Batteries

A. Any batteries carried in the aircraft shall be reviewed by NASA and determined to be safe

for flight based on cargo bay pressure and temperature range.

B. Batteries in the cargo bay shall not be actively charged or discharged during transportation.

C. Batteries with potential for toxic venting (such as NiCd) are not permitted in Cabin/Crew

areas.

D. Lithium batteries located in Cabin/Crew areas shall conform to 49 CFR 173.185.
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E. For batteries located in the Cargo Bay, battery state of charge shall be verified and 

documented prior to payload onloading. JSC-20793 or 49 CFR will define the permissible 

battery state of charge depending on the document used for approval.

F. Batteries conforming to JSC-20793 & JSC-63322 can be considered conditionally 

approved for flight but documentation will need to be provided for review.

G. Consumer-grade, Commercial off-the-shelf (COTS) batteries are generally approved for 

flight. (generally, ~100 Wh and below)

H. Loose (uninstalled) batteries shall be packaged and secured to be protected from damage.

I. Batteries not meeting requirements herein or that are outside of the 49 CFR limits will 

require further engineering evaluation and approval from NASA. Additional 

documentation will need to be provided.

J. Use the smallest size (minimum capacity) battery suitable for intended application, thus 

minimizing stored energy and electrolyte quantity.

K. Battery installations must withstand reduced pressures at altitude, normal aircraft structural 

loads and safely contain battery failure modes. Typical failure modes include cell rupture 

or explosion and cell overheating.

L. Battery containment: Battery containment and protection from mechanical abuse or battery 

manufacturing defects must be implemented to the level appropriate for the specific battery 

chemistry and installation specifics. For example, for Lithium-ion battery packs, 

overheating, fire, and explosion may result when the cells are damaged and are the primary 

concerns for containment design. However, for legacy liquid electrolyte batteries such as 

NiCd or NiMH, which may still see limited application in very narrow circumstances, 

failures may yield corrosive fluids and require a secondary battery enclosure to contain 

electrolyte should there be a leak. All battery containers shall be properly vented to 

a. accommodate rapid changes in cabin pressurization,

b. prevent the accumulation of explosive gasses, and 

c. prevent battery overheating.

M. Use a fuse or circuit breaker as close to the battery pack as possible.

N. Minimize hazards due to cell failure through use of isolation and/or bypass diodes, thermal 

cut out switches, electrolyte resistant wire insulation, etc.

O. Label battery housings with applicable safety warnings (such as corrosive/caustic liquid, 

flammable gas, high voltage or current capability).

P. Unattended battery charging on the aircraft is not allowed. Battery must be isolated when 

not in use. Battery approval is dependent upon the total aircraft mission configuration and 

assessed risk level for all potentially hazardous items on board.

Q. Approval will be for a particular mission series. Complete vendor battery specification and 

material safety data sheets must be submitted along with application information for AOD 

Engineering review and approval action. AOD Engineering approval will be required to 

allow unattended or overnight operation of battery-powered equipment in the aircraft.
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7.5.13 Uninterruptible Power Supplies

The structural integrity and circuitry guidelines above also apply to UPS batteries. All units will 

be subjected to safety inspection and battery handling procedures. The following specific 

requirements will be inspected:

A. A readily accessible emergency shutoff that disables all output power from the UPS shall

be implemented.

B. A Safety Data Sheet (SDS) must be supplied for the battery.

C. The battery must be a sealed lead acid (SLA) type with immobilized electrolyte. Non-SLA

batteries may be approved in only two circumstances:

a. If mission objectives are not achievable with a non-SLA battery pack.

b. If the user can demonstrate a history of manufacturing quality and reliability for the

constituent cells, and show adequate circuit protection for the cells and battery as a

whole is present. For guidance on specific safety considerations in different battery

chemistries, reference JSC 20793.

D. COTS UPS containment of SLA batteries is acceptable. Reference section 7.5.13 C. and 

battery containment guidance for more information on non-SLA requirements.

E. If the battery or battery interface to the UPS is not designed by the end user, the battery

must be within its valid shelf life, and the final wiring must be installed at JSC with an

aircraft inspector witness. If the battery is of the type that requires periodic maintenance,

adequate documentation must be presented that traces the last battery installation date and

subsequent UPS use and maintenance history.

F. If the battery was installed before arrival to JSC, the unit will be subject to a “covers

removed” inspection for general workmanship and compliance with wiring requirements,

containment, and isolation systems.

G. Along with an SDS for the battery, a copy of the owner’s manual for the UPS must be

provided. Provide circuit schematics detailing the battery/UPS interface, if available.

7.6 HAZARDOUS MATERIALS

Payloads containing hazardous materials which meet or exceed the requirements of approved 

NASA program safety requirements such as NSTS 1700.7, Safety Policy and Requirements for 

Payloads Using the Space Transportation System, or NSTS-1700.7 (ISS Addendum), Safety 

Policy and Requirements for Payloads Using the International Space Station, will be eligible for 

transportation on the SGT. The safety assessment reviews delineated in NSTS 1700.7, 

Chapter 3, System Program Requirements, Paragraph 304, Safety Assessment Reviews and 

Safety Certification, shall have been completed by the appropriate cognizant organization and 

associated safety compliance data package submitted four weeks prior to shipment, including 

any differences between in-flight monitoring requirements and any resulting ground 

handling/transportation flight safety devices required.

Hazardous cargo not destined for spaceflight shall be subject to safety criteria in NPR 6200.1, 

NASA Transportation and General Traffic Management. Waivers of this requirement can only 

be granted by NASA management. 
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Some examples of hazardous material/items are (this list is not all-inclusive):

• Flammable or Toxic Fluids

• Batteries

• Explosive or Pyrotechnic Devices

• Pressure Systems

• Charged Electrical Systems

7.7 NASA AIRWORTHINESS REVIEW

NASA has an airworthiness process that must be completed prior to flight. This review 

examines analyses, drawings, and other documentation to determine the system’s readiness for a 

safe and successful flight. The airworthiness review is usually held 1–2 weeks before the flight, 

depending on payload readiness. Customers shall provide the items listed in Table 9 as early as 

possible, but no later than four weeks prior to the airworthiness review date provided by NASA.

Table 9. Airworthiness Review Requirements Matrix

Item Title Notes

1 Stress Analysis Report (including 

thermal analysis and weld analysis,

if applicable)

Shall be signed by the customer and in a comprehensive, 

reviewable format. Refer to AOD 8594001 for stress report 

preparation guidance and expected content. PowerPoint 

presentations are not encouraged.

2 Payload Configuration Drawings Step 1: Shall be provided to NASA for review prior to 

fabrication.

Step 2: Shall be signed and formally released prior to 

airworthiness review.

3 Welding Procedures and Inspection 

Reports of Safety Critical Areas

Weld procedures shall be approved by NASA prior to 

welding. Final weld inspection reports shall be provided to 

NASA following welding.

4 Material Test Reports and 

Certifications

For safety critical materials and hardware.

5 Quality Sign-off Confirms the as-built hardware configuration matches the 

design. Ensures fasteners are torqued to specified values.

6 Measured Weight and CG x, y, z, and CG located relative to pallet lock pin hole #1.

Use AOD Form 424.

7 OCCP for Pressure Systems or 

Sealed Containers (if required)

Prepared by NASA with design and analysis input from 

customer.

8 Payload Installation Checklist Prepared by NASA with installation procedure input from 

customer.

9 Support Equipment List Smaller items to be shipped with the payload that support 

the payload (i.e., emergency equipment or an environmental 

control system). The customer shall provide dimensions 

and weight for each item.

10 Operations Risk Analysis Mitigation plan for hazardous items identified in Section 7.6 

Hazardous Materials. May include ground or flight testing 

(i.e., of data acquisition or environmental control systems).
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7.8 REPEAT AIRLIFTS

7.8.1 Payload Questionnaire Form

Repeat airlifts will have most of the items in Table 9 completed from previous efforts. However, 

the airworthiness documentation listed in Table 9 shall be resubmitted for each airlift iteration. 

Any changes in payload configuration must be communicated to NASA at the earliest 

opportunity while in coordination for subsequent airlifts. Analyses, drawings, installation 

checklists, and other pertinent documentation that have been revised since the initial delivery to 

NASA will be reviewed to ensure that flight readiness of the payload has not been altered. 

Changes in configuration may require the scheduling of an additional Airworthiness Review to 

receive authorization to proceed.

7.8.2 Quality Documentation

Quality documents with customer signature/stamps shall be resubmitted for each airlift for safety 

critical fasteners, modified structures, and added components. 

7.8.3 Recurring Inspection Plan

Pallets, tooling, and support structures shall be in airworthy condition and must be verified prior 

to each airlift by the customer and reviewed by NASA.

8.0 SUPPORT EQUIPMENT

8.1 PALLETS

8.1.1 48-Foot Cargo Pallet

The 48-foot cargo pallet (see Figure 22), used to secure cargo and interface with the aircraft, is 

constructed of aluminum and can be unpinned and separated into two sections: front (36 ft) and 

rear (12 ft) (refer to Table 10 for specifications). The cargo pallet has a pattern of threaded holes 

to accept tie down rings on approximately 24-inch squares, and lock pin holes that are spaced 

every 12 inches on each side that mate with the aircraft lock pins to secure the pallet to the 

aircraft.

NOTE

NASA has one 48-foot cargo pallet in inventory.

The 48-foot cargo pallet is constructed of an aluminum framework with an aluminum skin. 

Payload interfaces shall be designed to transfer loads through the main pallet framework and 

avoid placing loads on unsupported aluminum skin sections. 

Many payloads can be shipped on the 48-foot cargo pallet. Generally, cargo of nominal size, not 

exceeding the width of the pallet, can be tied down directly to the pallet. For shipment of 

outsized components, adapters of various heights can be bolted or chained to the pallet (refer to 

Section 8.3 Adapters). The cargo is then mounted onto the adapter at a level to fit the wider 

portion of the aircraft fuselage.
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To lift the pallet, such as to facilitate ground transportation, the 36-foot and 12-foot cargo pallet 

sections must be unpinned and lifted independently. See DWG 4091547, Lift Plan, 36-Foot 

Pallet Assembly, and DWG 4091548, Lift Plan, 12-Foot Pallet Assembly, for the pallet lift plans.

Table 10. 48-Foot Cargo Pallet Specifications

Item Value

Length 576 inches

Width 104.5 inches

Weight 2,015 lbs

Maximum Total Load

(including pallet weight) 46,000 lbs

Outboard Tie-Down Ring

(Large) 10,000 lbs29

Inboard Tie-Down Ring

(Small) 5,000 lbs

29 Limited by 10,000 lbs chain capacity. Outer pallet rows A and D can be increased to 15,000 lbs under certain conditions.
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Figure 22. 48-Foot Cargo Pallet30

30 See DWG 4000003.
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8.1.2 8-Foot Cargo Pallet 

The 8-foot cargo pallet (see Figure 23) has lock pin holes every 12 inches that interface with 

restraint pins and aircraft rollers to secure the pallet during flight (refer to Table 12 for 

specifications). These pallets can be used alone or in combination with the 48-foot cargo pallet 

(space permitting) for payload moves (e.g., the 8-foot cargo pallet has been used in the past to 

support environmental control units with larger payloads installed on the 48-foot cargo pallet).

NOTE

NASA has three 8-foot cargo pallets in inventory.

The 8-foot cargo pallet is an aluminum structure 96 inches long × 104.5 inches wide × 12.5 

inches high and weighs approximately 760 lbs. Threaded tie-down holes (i.e. tie-down ring 

receptacles) are located on the top surface to secure cargo to the pallet.

The 8-foot cargo pallet is constructed of an aluminum framework with an aluminum skin. 

Payload interfaces shall be designed to transfer loads through the main pallet framework and 

avoid placing loads on unsupported aluminum skin sections (refer to AOD 4091540, 8-Ft Pallet

Assembly, Cargo, Super Guppy, for detailed information).

Figure 23. 8-Foot Cargo Pallet31

Table 11. 8-Foot Cargo Pallet Specifications

Item Value

Length 96 inches

Width 104.5 inches

Weight 760 lbs

Maximum Total Load 5,000 lbs

Tie-Down Ring Capacity 5,600 lbs (any direction)

10,000 lbs (62 degrees to 90 degrees measured from pallet surface)32

31 See DWG 4091540.

32 Refer to AOD 4094015, 8-Foot Pallet Tie-Down Load Allowable.
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8.1.3 MightyGRIP Cargo Pallet

The MightyGRIP cargo pallet (see Figure 24) consists of 12, 4-foot modular sections, which can 

be bolted together to create a 48-foot assembly (refer to Table 13 for specifications). The pallet 

can accommodate multiple payloads simultaneously and enables multiple methods for 

integrating, bolting, and chaining. Segments can also be removed to reduce weight, with each 

segment weighing approximately 250 lbs. Each segment has threaded holes to accept tie down 

rings, with four locations every 2 ft. Lock pin holes are spaced every 12 inches along each side 

that mate with the aircraft lock pins to secure the pallet to the aircraft.

The load is distributed primarily through the base rails (see Figure 24). Seat tracks along the 

cross beams provide a flexible way to tie down light equipment or boxes. The deck panels are 

provided as a walking surface but are not designed to support items during flight.

NOTE

NASA has one MightyGRIP cargo pallet in inventory.

Generally, cargo of nominal size, not exceeding the width of the pallet, can be tied down directly 

to the pallet. For shipment of outsized components, adapters of various heights can be bolted or 

chained to the pallet (refer to Section 8.3, Adapters). The cargo is then mounted onto the adapter 

at a level to fit the wider portion of the aircraft fuselage.

To lift the pallet, such as to facilitate ground transportation, the segments must be bolted together 

and lifted at specific tie down points. See DWG 40-0000057, Lift Plan, MightyGRIP Pallet 

Assembly.

Figure 24. MightyGRIP Cargo Pallet33

33 See DWG 40-0000061 for dimensions and interface requirements.
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Table 12. MightyGRIP Cargo Pallet Specifications

Item Value

Length 576 inches

(bumpers not included)

Width 104.5 inches

Weight 2,771 lbs

Maximum Total Load (including pallet weight) 48,000 lbs

Outboard and Inboard Tie-Down Rings 10,000 lbs34

8.2 CARGO RESTRAINT HARDWARE

NASA-provided tie-down rings, cargo chains, and chain tensioning devices are typically used in 

conjunction with the pallets to secure cargo.

A. Cargo Chains

Chains conform to MIL-DTL-6458G Type I (MB-1) and are rated at 10,000 lbs maximum 

working load.

B. Tie-Down Rings

Tie-down rings conform to NAS1251 and have load ratings as follows:

1. 48-Foot Cargo Pallet

• Outboard Tie-Down Holes – NAS1251A25 (limited to 10,000 lbs maximum chain 

working load)

• Inboard Tie-Down Holes – NAS1251-5 (5,000 lbs maximum working load)

2. 8-Foot Cargo Pallet – NAS1251A25 (limited to 10,000 lbs maximum chain working 

load)

3. MightyGRIP Cargo Pallet – NAS1251A25 (limited to 10,000 lbs maximum chain 

working load)

C. Chain Tensioners

The chain tensioning devices conform to MIL-DTL-25959H Type III (MB-1) and are rated 

at 10,000 lbs maximum working load.

34 Limited by 10,000 lbs chain capacity.
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8.3 ADAPTERS

Cargo adapters can be used when necessary to elevate cargo to take advantage of a wider portion 

of the cargo bay. Several adapters are available, or custom adapters can be created for specific 

cargo. See Figure 25 for an example of the adapter structure.35

Figure 25. Adapter Weldment Assembly

The MiniGRIP was designed to be a simplified, lightweight adapter for transporting the Orion 

Heatshield. This adapter offers mass savings, requires fewer chains, and reduces wear on the 

pallet. The MiniGRIP cargo adapter weighs approximately 1,700 lbs, whereas the adapter shown 

in Figure 25 weighs approximately 4,800 lbs. Figure 25 shows the MiniGRIP cargo adapter with 

the heat shield payload and the adapter (by itself) installed on the 48-foot cargo pallet.36

35 See DWG 4091537, Adapter Weldment Assembly.

36 Contact AOD Engineering for guidance on adapter options and selection.
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Figure 26. MiniGRIP Cargo Adapter Installed on 48-Foot Cargo Pallet

9.0 CARGO LOADERS

During a typical airlift mission, cargo loaders are pre-positioned at the departure and destination 

airfields. There are several different types of loaders that can be used including the Cargo Lift 

Trailer (CLT), Rescue Loader, and United States Air Force (USAF) Tunner cargo loaders. The 

CLT and Rescue Loader are NASA assets, while the Tunner is a USAF asset that can be 

arranged as necessary.

For payloads with high vertical CGs or large surface areas, a Tip-Over Analysis is required. The 

tip over analysis will consider the payload bottom surface at the highest elevation on the loader 

deck, which is 12 feet. Further details of the Rescue Loader and CLT CGs and weights are 

provided in Table 13.
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Table 13. CLT and Rescue Loader Mass Properties37

Loader Weight Width

Rescue Loader 38,316 lbs 145.7 in

CLT 53,000 lbs 186.6 in

The Super Guppy is typically on- or off-loaded only during daylight hours. Weather conditions 

may restrict or prevent operations. The Flight Engineer and Loadmaster are responsible for 

determining if conditions will allow for safe operations. Wind limitations are typically 30 mph 

but may be decreased based on cargo loader usage, payload surface area, CG location, or 

additional factors. Refer to Section 10.2 for further guidance.

Any deviation from nominal operations with the Cargo Loaders must be approved by the Safety 

Office.

9.1 CARGO LIFT TRAILER

The CLT (see Figure 27) is a scissor type heavy lifting trailer that transports the pallet/payload 

short distances to the SGT’s location. It is towed/pushed short distances using a tug38 and moves 

at no greater than 5 miles per hour (mph). The CLT is a welded steel structure that transports

and lifts cargo weighing up to 55,000 lbs that is outfitted with a roller/rail system that matches 

the SGT. The CLT functions using a hydraulic system with hydraulically operated stabilization 

struts powered by a diesel engine. Hydraulic power is used for leveling the trailer, elevating the 

platform, and steering the front and rear wheel units. Electrical power is provided by a 12 VDC 

battery/generator system used for starting the engine and for remote control of hydraulic solenoid 

valves. The parking brake and suspension air supply come from an engine-driven air compressor 

and reservoir installed on the CLT.

The CLT is capable of being partly disassembled and transported by semi-trailer to distant 

airports when the need arises. This is accomplished first by removing the CLT outboard wheels. 

The CLT chassis is then placed on the bed of the semi-trailer and secured. The wheels are 

secured to another semi-trailer for shipment. When the CLT is loaded on the trailer, the 

shipment is 13 ft, 8 inches wide, which is an oversize load that requires extra travel time enroute. 

This should be taken into consideration when positioning equipment for permits, as well as

loading and unloading. Refer to Table 14 for CLT specifications.

37 Please contact NASA for vertical CG information of the loaders.

38 Tug must be capable of pushing or pulling a load of approximately 102,000 lbs.
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Table 14. Cargo Lift Trailer Specifications

Item Value

Length 581 inches

Width/Track (tires installed) 187 inches

Width (outside tires removed) 164 inches

Width (platform) 129.5 inches

Height (full raised deck position) 154.75 inches

Height (full down deck position, with 

air suspension)

63 inches

Height (full down deck position,

without air suspension)

57.75 inches

Weight 53,000 lbs

Cargo Carrying Capability 55,000 lbs

Maximum Towing Speed 5 mph

Brakes Air

Propulsion Towed at either end

Steering Hydraulic, both ends

Minimum Turning Radius 193 ft

Number of Tires 16

Tire Size 255/70R 22.5

Tire Type Highway/5 plies – one ply sidewall

Wheel Loads 40,560 lbs front

40,560 lbs rear (5,070 lbs per wheel)
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Figure 27. Cargo Lift Trailer

9.1.1 Additional CLT Considerations

The CLT cargo deck deflects when loaded; up to 3.0 inches of deflection has been observed at 

the center of the cargo deck when loaded (see Figure 28). The customer shall consider this 1G 

load case for their payload to determine if any detrimental and unacceptable stresses or 

deflections may occur. The worst-case scenario to be considered is a simply-supported beam 

with a 35-ft span.

Figure 28. Maximum Observed Deflection of CLT Deck Under Load
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9.2 RESCUE LOADER

The Rescue Loader (see Figure 29 and Figure 30) is a NASA asset that can transport loads up to 

55,000 lbs to and from the aircraft. The Rescue Loader is self-propelled (i.e., does not require a 

tug to be moved), and raises and lowers a load using a hydraulically actuated system.

The Rescue Loader is capable of being partly disassembled and transported by semi-trailer to 

distant airports when the need arises. When the Rescue Loader is loaded onto a trailer, the 

shipment is approximately 12 ft, 2 inches wide, which is an oversize load that requires extra 

travel time en route. This should be taken into consideration when equipment is being positioned 

for permits and loading and unloading. Refer to Table 15 for Rescue Loader specifications.
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Table 15. Rescue Loader Specifications

Item Value

Length 619.3 inches

Width 145.67 inches

Height (full raised position, top rail) 204.5 inches

Height (full raised position, top roller) 196.5 inches

Height (full down position) 59.06 inches

Minimum Turning Radius (front wheels turned only) 708 inches

Minimum Turning Radius (front and rear wheels turned) 433 inches

Weight 39,672 lbs

Cargo Carrying Capability 55,000 lbs

Figure 29. Rescue Loader
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Figure 30. Rescue Loader with Cargo

10.0 FLIGHT COORDINATION

10.1 AIRCRAFT SUPPORT

The primary aircraft support requirements are fuel, a tow tractor, an external power cart, and an 

air start unit.

• Fuel – The type of fuel required is JP-8, Jet-A, or JP-5. The flight crew will normally 

provide its own maintenance team; however, support commonly referred to as “transient 

maintenance” may be used, if available.

• Tow Tractor – The aircraft may require a tow tractor depending on availability and location 

of taxiways and ramp space. The tow tractor must be capable of pulling the aircraft with a 

ramp weight of approximately 171,000 lbs. The grade of the terrain over which the aircraft 

will be towed should be considered when sizing the tug.

• External Power Cart – The aircraft will require an external power cart (Hobart or equivalent)

to provide 28 VDC power. When carrying environmentally controlled payloads, provisions 

must be made to continuously power the aircraft on the ground.

• Air Start Unit – The aircraft requires an air start unit (USAF Type A/M32A-60A or 

equivalent) capable of a minimum output pressure of 35 pounds per square inch (psi).
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10.2 AIRFIELD CONSIDERATIONS

AOD will work with the customer to define acceptable runways and determine the feasibility of 

the aircraft landing and takeoff from both the loading and unloading site. The information 

required on the runway(s) and taxiway(s) includes the following:

• Runway Width and Length

• Type of Surface

• Altitude

• Specific Hazards

• Taxiway Width

• Taxiway Surface

• Runway and Taxiway Bearing Capacity

• Known Obstructions (e.g., fence openings, fence height)

The required runway length is a function of takeoff weight, altitude, and outside air temperature. 

The minimum runway length for ideal conditions (light takeoff weight, sea level and moderate 

temperature) is approximately 7,000 ft. In most circumstances, a 10,000 ft runway is sufficient.

Adequate ramp space is required for parking, loading, and unloading the aircraft. The ramp 

space should be as level as possible to facilitate nose opening and loading operations. The 

bearing strength of the ramp and taxiway should be sufficient to support the aircraft weight of 

approximately 171,000 lbs, with a footprint of 175 psi maximum.

The SGT has widely spaced main landing gear (48 ft), and as such requires sufficiently wide 

taxiways. A 50 ft taxiway may be appropriate for towing the aircraft, but a minimum of 75 ft 

taxiway width is recommended for when the aircraft is under its own power. These guidelines 

are not always sufficient given other unique airfield factors; consequently, AOD will assist with 

airfield selection.

Prevailing weather conditions at the loading and unloading sites should be considered for the 

time period that these operations are expected to be performed. Particular attention should be 

paid to wind, snow, and ice conditions (i.e., in-flight icing, ground deicing). En route weather 

problems are the responsibility of the flight crew.

A desired aircraft loading time will be established early in the flight planning schedule; this time 

will be adhered to as closely as equipment and weather permit.

NOTE

Early morning wind conditions generally control the 

loading times.
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As the actual time for aircraft arrival at the loading site nears, NASA will update the specific 

arrival time. For both aircraft loading and unloading, the aircraft is typically positioned so that 

the left wing points toward the direction of the prevailing wind so that wind loads are reduced on 

the nose when it is opened (see Figure 7). The maximum wind speed allowed for nose opening 

is 30 mph (26 knots) with approval by the flight crew based on a real-time assessment of airfield 

and weather conditions. The forecast for winds and weather must be verified prior to opening 

the nose to ensure that the 30 mph (26 knots) limit will not be exceeded while the nose is open.

10.3 EN ROUTE STOPS

Stops en route may be required to refuel the aircraft or rotate the flight crew. The flight crew

will determine the most suitable airfields for this purpose. The number of fuel stops required is a 

function of maximum allowable takeoff weight and the payload weight; heavier payloads 

operating out of high-altitude airports will require more fuel stops. If the customer desires a 

specific stop en route, this should be specified early in the flight planning schedule to enable the 

flight crew to evaluate the location.

10.4 SPECIAL PAYLOAD REQUIREMENTS

Any special requirements during loading, transport, or unloading of the payload will require 

coordination to determine the availability of the requested support in the aircraft. These may 

include special environmental or power provisions based on payload requirements.

11.0 AIRLIFT PROCESS, ROLES, AND RESPONSIBILITIES

This section provides information about the airlift process as well as the specific responsibilities 

for both NASA and SGT customers. Official requests for use of the SGT transportation system

shall be submitted to the SGT Program Manager.39

11.1 THE AIRLIFT PROCESS

Once initial conversations have started, NASA will provide the potential customer with the 

following initial Super Guppy Data Package:

• Super Guppy User’s Guide

• Drawings and CAD/FEM models of the following:

− The Super Guppy cargo volume (CAD model only)

− Pallets and other fixtures as required

− MightyGRIP and Super Guppy Floor Finite Element Model

• AOD Form 429, Super Guppy Payload Questionnaire Form

Upon request for further information, NASA will provide documents relating to temperature, 

vibration, and dynamic environments within the Super Guppy cargo bay.

39 See https://www.nasa.gov/specials/jsc-aircraft-ops/guppy.html#contact
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Using the Payload Data Package Form, information and related documents shall be provided to 

NASA by the dates listed to ensure all items are addressed prior to the Airworthiness Review. As 

documents are revised, the Payload Questionnaire Form shall be updated and provided to NASA 

with the appropriate document revisions.

NOTE

A checklist for airlift planning and role definitions is 

provided in Appendix B.

11.2 NASA RESPONSIBILITIES

AOD has the overall responsibility for the scheduling, mission planning, airworthiness, and 

detailed logistics planning for SGT missions. This responsibility entails the direction and 

scheduling necessary to ensure the safe and expeditious arrival of cargoes at destinations. This 

includes call-off authority for situations related to safety and weather. Aircraft loading, 

unloading, and in-transit care of the cargo are the joint responsibility of both AOD and the 

customers.

The procedures outlined in this section are applicable to all customers, including users other than 

NASA. The AOD organization/person receiving the customer request for use of the aircraft will 

forward copies of all documentation to the SGT project pilot and the AOD Engineering Branch.

11.2.1 Flight Crew

AOD is responsible for providing the flight crew, which typically includes a pilot, a copilot, two

FEs, and a loadmaster.

11.2.2 Ground Crew

AOD personnel perform all aircraft maintenance. NASA is responsible for the personnel 

required to load and unload the aircraft.

11.3 CUSTOMER RESPONSIBILITIES

Customers are responsible for the following actions:

• Identifying the cargo and estimated move dates.

• Identifying the desired departure and arrival airfields and assist NASA in identifying 

available aircraft support at these locations.

• Providing a cargo-specific shipping fixture for the aircraft.40

• Providing cargo specific environmental control, if required.

• Providing all airworthiness items identified in Section 7.7, NASA Airworthiness Review.

40 NASA will provide design guidance as required.
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11.3.1 Customer Flight Support Personnel

Due to the extensive modification of the SGT, NASA does not recommend that customer 

personnel fly on board. If the customer has a firm requirement for non-NASA flight support 

personnel, the individuals must be medically cleared by the NASA flight medicine clinic and 

will be required to complete a short physiological training course, which may be arranged by 

NASA at JSC. Additionally, customer flight support personnel must have boarding orders 

approved by the Flight Operations Directorate.

NOTE

Request for boarding orders requires considerable advance 

notice.
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APPENDIX A

ACRONYMS AND ABBREVIATIONS

A Amp

ACL Allowable Cabin Load

AGL Above Ground Level

AISC American Institute of Steel Construction

AOD Aircraft Operations Division

ASTM American Society for Testing and Materials

AVG Average

AWS American Welding Society

BW Bandwidth

C Celsius

CAD Computer Aided Design

CCPD Configuration Control Panel Directive

CG Center of Gravity

CLT Cargo Lift Trailer

COTS Commercial off-the-shelf

dB decibel

DOT U.S. Department of Transportation

DWG Drawing

ECS Environmental Control System

ECU Environmental Control Unit

EDMS Electronic Document Management System

EQ Equal

F Fahrenheit

FAR Federal Aviation Regulation

FE Flight Engineer

FEM Finite Element Model

FS Factor of Safety

Fuselage Station

ft feet

ft/min feet per minute

ft-lbf foot-pounds force
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G gravity

GVT Ground Vibration Testing

HYD Hydraulic

Hz Hertz

IAW in accordance with

in-lbs inch-pounds

ISS International Space Station

JPR JSC Procedural Requirement

JSC Johnson Space Center

L/H Left Hand

lbs pounds

lbs/in pounds per inch

lbs/sqft pounds per square feet

MAX Maximum

MIN Minimum

mph miles per hour

MS Margin of Safety

N Newton

No. Number

N/m2 Newton per square meter

NASA National Aeronautics and Space Administration

NFPA National Fire Protection Association

NPR NASA Procedural Requirement

NSTS NASA Space Transportation System

OCCP Operation & Configuration Control Panel

P/N Part Number

PL place

PQF Payload Questionnaire Form

psi pounds per square inch

psi/min pounds per square inch per minute

psia pounds per square inch absolute

PV/S Pressure Vessels/Systems
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Qty Quantity

R/H Right Hand

R Radius

REF Reference

RMS root mean square

SDS Safety Data Sheet

SEC seconds

SGT Super Guppy Transport

SLA Sealed Lead Acid

SOP Standard Operating Procedure

SPCS Spaces

SPL Sound Pressure Level

Sut Material ultimate tensile strength

Sy Material yield strength

THK Thick

TOD Time of Day

TWR Tower

TYP Typical

ult Ultimate

UNF Unfinished

UPS Uninterruptible Power Supply

U.S. United States

USAF United States Air Force

USG U.S. Gallon

VAC Volts Alternating Current

VDC Volts Direct Current

Wh Watt hour

yld yield

ZFW Zero Fuel Weight

& ampersand

′ foot

′′ inch
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° degree

∅ diameter

+ plus

@ symbol indicating “at”

= equal

- minus

μF microfarad

× multiplication

# number sign

≥ greater than or equal to

± plus or minus
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APPENDIX B

AIRLIFT PLANNING CHECKLIST

This checklist is designed to be a guide for the customer during the payload planning stage. It is 

not exhaustive and is subject to change depending on the unique nature of each mission.

User’s

Guide 

Reference 

Section

Responsible 

Individual Statusa Notes

Payload Considerations

Has the estimated payload weight 

and Center of Gravity (CG) been 

provided to NASA?

6.5

Is the total cargo weight within 

capacity, based on the flight path? 

[in no case greater than 

48,000 pounds (lbs)]

6.7

Does the installed payload meet the 

longitudinal and vertical CG 

requirements for the entire aircraft?

6.5

Has adequate clearance (payload 

to SGT) been demonstrated? 6.4, 7.5.1

Is the design and/or identification of 

all airlift components (fixtures, 

dunnage, etc.) complete?

—

Does the payload have the 

necessary features to interface with 

the pallet? If a NASA pallet is not 

used, does the payload have 

provisions to interface with aircraft 

floor rollers and lock pin interfaces?

7.5

Has the payload been analyzed for 

flight load factors and crash load 

factors?

6.8

Do all cargo elements have a 

positive Margin of Safety (MS)? 7.2

Can the weight of the integrated 

payload be distributed on the cargo 

bay roller system within the aircraft 

floor load limits?

6.7, 7.5.2

Do all safety critical fasteners have 

a locking feature? 7.5

Has differential thermal expansion 

been considered for the shipping 

fixture?

7.5

Has the impact strength of 

materials subject to brittle transition 

at low temperatures been tested?

7.5

a Open, Closed, or Revisit

b Required for Airworthiness Review
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a Open, Closed, or Revisit

b Required for Airworthiness Review

User’s

Guide 

Reference 

Section

Responsible 

Individual Statusa Notes

Payload Considerations (Continued)

Has a lift plan been developed? —

Is power required to be provided to 

the payload? 6.3

Is an Environmental Control 

System/Unit (ECS/ECU) is required 

for the payload?

6.9

Are any sensors or data collection 

devices required? 6.3

Is a payload cover required for 

transport? 7.5.11

Is the payload covering adequately 

vented to account for pressure 

differentials?

—

Are there any hazardous items or 

pressure systems included in the 

payload?

7.6

Are any materials exposed to 

possible ignition sources flame 

retardant?

7.5.11

Have all batteries been reviewed by 

NASA and deemed safe for flight? 7.5

Have weld procedures for safety 

critical areas been approved by 

NASA prior to welding?b

7.5.7

Payload Documentation

If pressure systems are included in 

the payload, has NASA provided 

pressure systems approval and/or 

generated an Operation & 

Configuration Control Plan

(OCCP)?b

7.5, 7.6

Do safety critical materials and 

hardware have material test reports 

and certification paperwork?b

7.5

Have stress analysis report(s) been 

delivered to NASA covering the 

prescribed topics, including thermal 

analysis and weld analysis?b

7.3, 7.5

Has the operations risk analysis 

been completed for hazardous 

items included in the payload?b

7.7
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User’s

Guide 

Reference 

Section

Responsible 

Individual Statusa Notes

Payload Documentation (Continued)

Have payload configuration 

drawings been provided to NASA 

for review prior to fabrication?b

7.7

Have payload configuration 

drawings that have been provided 

to NASA been signed and formally 

released?b

7.7

Have all electrical interfaces been 

identified and associated wiring 

schematics been provided to 

NASA?

6.3

Have all electrical power 

requirements, including steady 

state, peak, and in-rush currents 

been provided to NASA?

7.6.12

Has NASA Quality signed off, 

confirming that the as-built 

hardware configuration matches the 

design?b

7.7

Have weld procedures and 

inspection reports of safety critical 

areas been provided?b

7.5.7

Have final as-measured mass 

properties, including total cargo 

weight and CG location in all three 

directions (x, y, z) been provided to 

NASA?b

7.4

Has the payload installation 

checklist been completed?b 7.7

Has a list of additional items 

(besides the primary payload) to be 

flown been provided to NASA?b

7.7

Have safety assessment reviews 

been completed and compliance 

data package submitted 4 weeks 

prior to shipment?

7.6

Does any documentation need to 

be transported with the payload? —

a Open, Closed, or Revisit

b Required for Airworthiness Review
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User’s

Guide 

Reference 

Section

Responsible 

Individual Statusa Notes

Pre-Mission Activities

Who are the mission planning leads? 11

What are the departure and arrival 

airports? 10.2

What is the planned mission start 

date? —

Has an airlift mission timeline been 

created? —

Will a final review be required prior 

to the airlift? —

Has the NASA airworthiness review 

been completed? 7.7

Is a customer representative 

required to fly on board? (not typical) 11.2

Departure Airfield Activities

Who is the primary contact at the 

departure airfield? —

What is the on-load date? 11.2

Has a location at the airfield been 

identified for on-loading activities? —

Have permits/badges been arranged 

to access airfield? Has a personnel 

list been provided to NASA?

—

Has ground transportation to the 

airfield been coordinated? —

Have United States (U.S.) 

Department of Transportation (DOT)

permits for ground transportation 

been coordinated?

—

Has a crane been secured for onload activities? Loader preparation

(i.e., personnel tying down load)?

—

Are there any airfield conflicts/

specific weather concerns at the 

departure airfield?

10.2

What loader will be used for onloading activities? Readiness

(i.e., servicing, coordination with 

USAF)?

—

a Open, Closed, or Revisit

b Required for Airworthiness Review
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User’s

Guide 

Reference 

Section

Responsible 

Individual Statusa Notes

Departure Airfield Activities (Continued)

When will the loader arrive at the 

airfield? —

Will fuel be required for the SGT at 

departure airfield? 10

Is the required ground support 

equipment available? 10.1

Is any public affairs interaction 

planned? —

Arrival Airfield Activities

Have ground vehicles been 

coordinated for the flight crew? —

Who is the primary contact at the 

arrival airfield? —

What is the off-load date? 11.2

Has a location at the airfield been 

identified for off-loading activities? —

Have permits/badges been arranged 

to access airfield? Has a personnel 

list been provided to NASA?

—

Has payload ground transportation 

from the airfield been coordinated? —

Have U.S. DOT permits for ground 

transportation been coordinated? —

Has a crane been secured for offload activities? Loader preparation

(i.e., personnel tying down load)?

—

Are there any airfield conflicts/

specific weather concerns at the 

arrival airfield?

10.2

What loader will be used for offloading activities? Readiness (i.e., 

servicing, coordination with USAF)?

—

When will the loader arrive at the 

airfield? —

Will fuel be required for the SGT at 

arrival airfield? 10

Is required ground support 

equipment available? 10.1

Is any public affairs interaction 

planned? —

Have ground vehicles been 

coordinated for the flight crew? —

a Open, Closed, or Revisit

b Required for Airworthiness Review
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Additional Notes: