Building while flying: Keeping airport operations on through construction
Delivering an airport upgrade while maintaining operational continuity is a complex and challenging task. At AECOM, our decades of global aviation experience mean we manage these projects with minimal disruption to airport operations, airlines and the travelling public. In this article, I’ll discuss insights on keeping airports running during major construction upgrades using our recent work on San Diego Airport’s New Terminal 1 Program as a case study. As the USA’s busiest single-runway airport, this high-volume, highly constrained site required creative logistics.
Involving builders early
The San Diego International (SAN) Airport New Terminal 1 Program is comprised of multiple projects with varying procurement and delivery models, including the major Terminal & Roadways project and several substantial enabling works.
We played a key role in integrating these components by aligning scopes, sequencing work and adapting to changes. Choreographing the complexity of these components was a significant challenge. The Progressive Design Build delivery method (Early Contractor Involvement, as it’s known in Australia) played a crucial role in overcoming this challenge, all the while dealing with the uncertainty of COVID and the post-COVID marketplace.
This approach enables agility, continuous evaluation, and specialist input from designers and builders throughout. With over 15 years of partnership with the San Diego County Regional Airport Authority (SDCRAA), our depth of knowledge about the facility and trusted collaboration meant we could help guide decisions and advise client staff through informed recommendations.
Delivery challenges in a constrained live airport site
It was a puzzle that we kept having to solve.
SAN Airport is a highly constrained site, so we needed to get creative with land and construction site logistics. It was like a puzzle we kept solving through moving pieces around until the picture came together.
For example, originally trades were parking off-site and bussing in each day, which was costly and disruptive to site operations. We proposed to the client to park them in the new car park. Although initially apprehensive due to a potential loss of revenue from customers, we supported development of a cost analysis and found it would be more cost-effective and efficient for the client.
Due to a commitment to the state of California that by 2035, no rainwater will leave the airport, we managed the design and construction of a 900,000-gallon underground cistern as part of the airside project. This project was adjacent to the new terminal, so needed to be carefully considered in building and roadway construction sequencing.
The airport site sits right on the ocean, which presented major groundwater challenges. We faced dewatering issues, as we couldn’t lower the water table to the depth needed to construct the cistern. This caused construction delays, which also impacted other project’s sequencing and schedule milestones.
Rather than continuing, we stepped back and decided the best path forward was to redesign the cistern, so it didn’t go as deep. While it may have seemed like a drastic decision, it allowed us to raise the bottom elevation to a point where the dewatering became achievable.
While a change order was involved, the path decided was the most beneficial to the overall program.
The success of such project’s hinges on strong program management and collaboration with all stakeholders. At SAN Airport, we worked closely with our client and partners, building trust and understanding that allowed us to navigate the inevitable challenges and unknowns in a mutually beneficial way. This collaborative spirit is essential to delivering successful airport upgrades while maintaining operational continuity.
Partnerships for success
In a Progressive Design-Build delivery, the most important decision you will make is who you select as your Design-Build partner.
As partners, our approach is to constantly look for ways to improve on plans, reevaluate ideas and provide innovative, informed alternatives for the client to decide upon. We find this allows us to create win-win solutions which leads to the best outcomes.
We value having a whole team that is constantly searching for new ideas to move projects forward as quickly as possible. We value that in our Design Build partners too. They bring ideas on how to do things faster. When partners work well together and collaborate openly and transparently, they help projects succeed.
Must haves in a partner
Mindset and empathy are required on both sides. We must set aside our company names and trust that the decisions we make won’t harm each other. We must also respect each other’s need to be profitable businesses.
The contract is designed to create that alignment. For example, having savings participation opportunities sewn into contracts. This way, our partners are incentivised to find the more cost-efficient way of doing things, because they benefit as well.
Most important elements for success in the SAN Airport live terminal environment
- Our team and the expertise we bring in collaboration with our partner design builders. Our understanding of the facility and aviation operations. These give us the foundations needed to explore ideas and alternatives.
- Trust – it’s essential. Trust builds on the foundations and allows us to work through the inevitable challenges and unknowns that all complex projects will encounter, in a healthy and mutually beneficial way.
The new SAN Terminal 1 opens September 2025.