Starbase Implements Space Age BMP's to Mitigate Trackout
SpaceX Implements FODS at Starbase As Stabilized Construction Entrance BMP
In 2014, SpaceX initiated the development of Starbase its private launch facility. Following a comprehensive evaluation process that considered multiple potential sites across the United States, SpaceX chose Boca Chica located south of San Antonio on the southern tip of the state, just outside of Brownsville, Texas. The site was chosen due to the lower latitude which provides an advantage for orbital launches as well as the supportive regulatory environment in Texas.
Since its initial construction in 2014, Starbase has evolved from assembly and testing site into a fully operational launch complex, serving as the primary hub for SpaceX's ambitious Starship program. Early development efforts focused on site preparation, infrastructure installation, and environmental compliance. By 2019, the facility had expanded with critical structures, including high bays for rocket assembly, a launch mount, and a fuel farm to support Starship test flights. Another recent investment of 100 million dollars enabled the construction of a five-story office mezzanine and a special-use factory totaling 1 million square feet. The site has hosted prototype launches, including high-altitude tests in 2020 and the first orbital test flight in 2023. As SpaceX continues to push the boundaries of space exploration, the site has grown to support the expanding workforce, a new control center, and additional launch infrastructure to accommodate higher launch frequencies.
SpaceX has petitioned to incorporate the launch site, now known as Starbase, into an official city. This move aims to support workforce growth and the development of necessary amenities, including utilities, schools, and infrastructure for employees and the surrounding community. Incorporating would also allow local governance to oversee continued construction and operations more effectively.
Alongside these developments, the company has navigated regulatory challenges and implemented sustainable construction and operational best practices to mitigate environmental impact. Starting in 2014, the Federal Aviation Administration (FAA) and the Texas Commission on Environmental Quality (TCEQ) have closely monitored the safety and environmental impact of the site. To meet the regulatory requirements established by the Clean Water Act and the Texas Pollutant Discharge Elimination System (TPDES), Best Management Practices (BMPs) have been integrated into the operational procedures at the site. With each new development, the Stormwater Pollution Prevention Plan (SWPPP) is reviewed to ensure the best practices are utilized to maintain strict environmental compliance and protect the surrounding ecosystem.
FODS Deployed On The Construction Of The New Launch Pad
Mitigating Environmental Impact
The Starbase facility, located near the Gulf of Mexico, is home to a unique ecosystem, including coastal wetlands, migratory bird pathways, and diverse marine life. Large-scale projects like Starbase often face environmental compliance challenges. The tight launch windows and budget constraints of space exploration requires SpaceX to take a comprehensive and proactive approach to regulatory compliance to avoid unexpected delays.
The SWPPP outlines techniques and processes that will be implemented to mitigate potential sources of water pollution, with the primary contaminant being regular soil. Soil stabilization techniques and erosion and sedimentation prevention techniques are used on these large-scale operations to prevent soil from being tracked onto roadways which can then enter stormwater drains. Traditional methods, such as rock-stabilized construction entrances require the introduction of aggregate to the site which may not be desired in some applications. Traditional rock entrances can also be cost and labor intensive over time, requiring frequent maintenance, and may not preform consistently. SpaceX decided to explore modern solutions that could alleviate these issues with traditional techniques.
With these unique challenges and heightened scrutiny from regulatory agencies, SpaceX chose the FODS Trackout Control System as the BMP for the entrance and exit points of the launch site complex. The FODS system can perform consistently for years on end and provides a predictable and effective solution for trackout control. FODS is proud to have its Reusable Construction Entrances System on the ground to mitigate environmental impact during the launch site’s operations. The implementation of FODS Composite Trackout Control System at SpaceX demonstrates the company’s commitment to safety and efficient operations.
Why FODS Trackout Control System?
FODS mats are an advanced trackout control system with a proven track record in the aviation, industrial and construction industries. The system is designed to dislodge and capture sediment and debris from vehicle tires before they exit a construction site. Unlike traditional gravel-based methods, these durable, non-porous mats are engineered for long-term reusability, making them an eco-friendly and cost-effective alternative.
Trackout—the transport of mud, dirt, and debris from construction sites onto public roads—is a significant environmental concern in large-scale industrial sites like Starbase. Traditional trackout control methods, such as aggregate based stabilized construction exits made using aggregate rock pads or gravel entryways, are often inefficient, labor-intensive, and can cause additional environmental strain due to frequent replacement and material transportation. The FODS system is a durable, reusable solution that is engineered to minimize soil displacement and prevent debris from being tracked from the launch site by trucks, cars, and other vehicles leaving the area.
A nearby 2019 study conducted by the Harris County Flood Control District, which involved over 30,000 vehicles exiting the site, found that the use of FODS Reusable Construction Entrance System reduced trackout from construction sites by 59% and a 94% reduction in maintenance and labor vs. traditional Stabilized Construction Exits made with aggregate.
FODS Trackout Control System Installed At Launch Site
FODS mats offer a superior alternative to traditional rock pads by minimizing soil disruption, as they lay on top of the ground without requiring extensive excavation, which can aid in preserving native vegetation. Constructed from high-strength, military-grade materials, these mats provide exceptional durability, withstanding the heavy traffic of construction vehicles, and space-related transport equipment. Their quick deployment and easy relocation ensure flexibility, aligning with SpaceX's dynamic construction and operational schedules. Additionally, FODS mats enhance environmental compliance by reducing sediment discharge and dust generation, helping SpaceX meet regulatory standards set by agencies like the Texas Commission on Environmental Quality (TCEQ) and the Environmental Protection Agency (EPA).
As SpaceX continues to develop Starbase into a premier launch facility for the next generation of space travel, including its highly anticipated Starship program, its commitment to environmentally responsible construction practices will be crucial in securing the site's long-term viability.
Conclusion
The use of FODS Reusable Construction Entrances at SpaceX's Starbase construction site underscores the company's dedication to environmental protection and regulatory compliance. As the space industry continues to push the boundaries of innovation, sustainable practices like these will be instrumental in ensuring that progress does not come at the expense of ecological preservation.
With the Starship program set to revolutionize space travel, SpaceX's approach at Starbase serves as a benchmark for other aerospace companies looking to integrate environmentally friendly construction solutions. The success of FODS trackout control mats in Brownsville, TX, may inspire broader adoption of sustainable construction practices across the industry, proving that space exploration and environmental responsibility can go hand in hand.
ABOUT FODS, LLC.
Based in Centennial Colorado, FODS is working to replace ineffective and costly traditional rock stabilized construction entrances, saving you time and money. Our proprietary mat design works to effectively remove debris from your vehicle tires without damaging the tire or the ground’s surface. FODS Vehicle Trackout Controls BMP mats are 100% Made In the USA and 100% recyclable.
To find out more information on how we can help your project stay on schedule and in compliance contact 844-200-3637 or email us at info@getfods.com.