[boran_blok]

Imho there are two solutions for this problem, one might be possible with the current shuttle design but might be impossible due to physics, the second is for the next shuttle design.

First the maybe now possible one: why not install a protective jacket around the heatshield of the shuttle ? it doesnt need it when lifting off, only when coming down.

Second, make it so that in the next shuttle the fuel tanks and booster rockets are on the less vulnerable side, this should be the backside for the current space shuttle, or maybe even the sides.

both solutions however are quite expansive I think so it'll be for the next shuttle.