Project Overview: Transforming Air Cargo Ground Operations

The San Diego cargo handling and truck deck project represented a comprehensive infrastructure development at one of Southern California’s busiest air cargo facilities. The scope extended far beyond simple equipment installation, encompassing civil engineering, structural construction, sophisticated material handling systems, and complex electrical distribution—all while maintaining continuous cargo operations at an active international airport.

Project Specifications at a Glance

Location: San Diego International Airport Air Cargo Facility
Client: Leading Global Parcel Carrier
Key Metrics:

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For more information about this project or related topics, contact Jeff by email or call directly at 925.984.0062.

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The Challenge: Building in an Active Airport Environment

Operating within an airport environment presents unique challenges to our Specialty Trade Services Team that extend beyond typical construction projects. Every aspect of the work required coordination with multiple stakeholders:

• Port Authority Requirements: Continuous communication and compliance with airport operations
• Security Protocols: SANR (Security Approval/Acknowledgement Not Required) designation required specific procedures
• Operational Continuity: Zero disruption to ongoing cargo operations
• Regulatory Compliance: Navigation of federal, state, and local requirements
• Infrastructure Integration: Seamless connection to existing sort center facilities

Electrical Distribution Design

• Comprehensive Division 26 Electrical specifications
• Site-wide electrical layout with integrated grounding plans
• Feeder service calculations for heavy-duty equipment loads
• Branch circuit design for distributed Material Handling Equipment (MHE)

Navigating Complex Permitting

The permitting process for airport facilities requires exceptional attention to detail and stakeholder coordination. SilMan’s team managed a multi-tiered approval process:

1. Tenant Improvement (TI) Application: Supporting the client through initial filing and subsequent modifications
2. Airport Authority Plan Check: Iterative review process with continuous updates and modifications
3. City Review Process: Final approvals following 90% Airport Authority sign-off
4. California PE Certification: Professional Engineer stamps for each discipline, ensuring code compliance

This systematic approach to permitting eliminated delays and ensured all stakeholders remained aligned throughout the approval process.

Phase 2: Electrical Distribution and Controls

The electrical infrastructure represented one of the project’s most complex elements, requiring integration with existing systems while providing capacity for future expansion.

As plans progressed, the team identified that local power would not support the fully operational facility. The nearest adequate power source lay across a public street, significantly increasing the logistical challenges of the project. SilMan’s engineering team developed a comprehensive solution that minimized traffic disruptions and the progress of site work while ensuring long-term reliability.

Power Distribution Architecture

SilMan designed and installed a comprehensive electrical distribution system:

Primary Components:

• New feeder lines from the existing sort center
• Dedicated distribution panels for MHE systems
• 480V and 120V power distribution
• Integrated grounding systems meeting airport standards

Load Management:

• Calculated loads for simultaneous equipment operation
• Power factor correction for efficiency
• Surge protection for sensitive electronics
• Emergency stop circuits throughout the facility

Lighting and Utility Systems

Beyond equipment power, SilMan provided complete utility infrastructure:

Illumination Systems:

• Two LED tower lights for area coverage
• Task lighting at equipment positions
• Emergency lighting meets the code requirements
• Photocell controls for energy efficiency

Data Infrastructure:

• CAT6 cabling throughout the facility
• Dedicated raceways for future expansion
• Network connections for scale data integration
• Wireless access point infrastructure

Phase 3: Site Preparation and Civil Construction

With permits secured, SilMan mobilized for one of the project’s most critical phases: transforming an active airport location into a construction site while maintaining operational integrity.

Strategic Site Preparation

The site preparation phase demonstrated SilMan’s commitment to safety and operational excellence:

Safety and Security Planning

• Development of site-specific safety plans tailored to airport operations
• Creation of construction site security protocols meeting federal requirements
• Implementation of a comprehensive Site-Wide Pollution Prevention Plan (SWPPP)
• Installation of barriers and identification systems for construction zones

Underground Utility Investigation. Before any excavation, SilMan’s team conducted thorough subsurface investigations:

• USA ticket coordination for utility marking
• Advanced scanning for unknown utilities
• Mapping of existing infrastructure to prevent conflicts
• Development of protection strategies for in-place systems

Civil Infrastructure Development

The civil construction phase showcased SilMan’s self-performance capabilities across multiple disciplines:

Excavation and Earthwork

• Removal and off-haul of existing hard surfaces
• Excavation to 21 inches below finished grade
• Installation of 17 inches of virgin ¾-inch base rock
• Achievement of 95% modified Proctor compaction throughout

Concrete Slab Construction

The centerpiece of the civil work involved constructing a robust concrete platform capable of supporting heavy cargo operations:

• 180 feet by 15 feet reinforced concrete slab
• 4,000 PSI concrete mix for maximum durability
• Sophisticated reinforcement design for dynamic loads
• Precision finishing to ensure proper drainage and equipment mounting

Asphalt Restoration Following underground utility work, SilMan restored all affected surfaces:

• Replacement of asphalt within 18 inches of construction areas
• FAA-specification asphalt mix for airside applications
• Integration with existing pavement for seamless transitions

Phase 4: ULD Handling Equipment Installation

The heart of the transfer terminal lies in its sophisticated material handling systems. SilMan’s expertise in equipment integration ensured optimal performance from day one.

Scissor Lift Systems

Ten Southworth Air Cargo Lift units (Model AGFS15-49) formed the backbone of vertical cargo movement:

Technical Specifications:

• Platform dimensions: 120″ x 156″ (10′ x 13′)
• Specialized air cargo design for aviation containers
• Integrated floating bumpers for equipment protection
• Hydraulic power units with redundant safety systems

Installation Excellence:

• On-site OEM support during critical installation phases
• Precision alignment with caster deck systems
• Integration with facility power and control systems
• Comprehensive testing and commissioning protocols

Caster Deck Infrastructure

Forty-one Talos Engineered Products caster decks created a flexible cargo staging system:

System Components:

• Individual deck dimensions: 108″ x 132″ (9′ x 11′)
• 164 heavy-duty caster deck supports
• Integrated skirt systems for safety and aesthetics
• Design per FedEx Drawing No. OM7J0002 specifications

Operational Features:

• 360-degree cargo mobility
• Quick reconfiguration for varying container sizes
• Durable construction for 24/7 operations
• Minimal maintenance requirements

Precision Scale Integration

Three Avery Weigh-Tronix scales provided critical weight verification capabilities:

Technical Details:

• Model: AWT05-500926 Single Caster Scale
• Capacity: 20,000 pounds
• Dimensions: 131″ x 107″ platforms
• ZM303 indicators with remote mounting capability

Calibration and Certification:

• On-site OEM technician calibration
• Legal-for-trade certification
• Integration with facility data systems
• Redundant measurement verification

Safety and Access Infrastructure

Comprehensive safety systems ensured worker protection and operational efficiency:

Fixed Infrastructure:

• Three engineered fixed platforms with OSHA-compliant railings
• Three sets of industrial stairs meeting airport specifications
• Twelve embedded bollards for equipment protection
• 180 feet of fixed deck bumpers with integrated rollers

Protective Systems:

• 50 feet of C12 bumper systems at critical points
• Container stops at 60 strategic locations
• Complete perimeter guarding
• Emergency egress pathways

Lessons Learned: Building on Success

The San Diego Air Cargo Transfer Terminal project reinforced several critical insights for complex airport infrastructure projects:

Flexibility in Execution

The primary power change order demonstrated that successful projects require:

• Robust contingency planning
• Strong stakeholder relationships
• Technical depth to develop alternatives
• Project management skills to maintain momentum

Integration Complexity

Airport projects demand exceptional coordination:

• Early engagement with all stakeholders
• Comprehensive underground utility investigation
• Flexible scheduling for operational requirements
• Clear communication protocols

Value of Self-Performance

SilMan’s integrated delivery model proved essential:

• Single-source accountability for results
• Rapid response to changing conditions
• Consistent quality across disciplines
• Efficient problem resolution

Setting the Standard for Airport Infrastructure Excellence

The ULD handling facility provided in San Diego stands as a testament to what’s possible when engineering excellence meets operational expertise. In an environment where precision, safety, and reliability converge at the speed of global commerce, SilMan Industries demonstrated why leading logistics providers trust them with their most critical infrastructure investments.

This project showcased every element of SilMan’s integrated capabilities:

• Engineering Excellence: From initial design through as-built documentation
• Construction Expertise: Self-performed work, ensuring quality and schedule
• Technical Depth: Solving complex challenges like the primary power installation
• Project Management: Coordinating multiple stakeholders in a demanding environment
• Operational Understanding: Delivering solutions that enhance daily operations

For organizations facing complex infrastructure challenges—whether in airports, distribution centers, or industrial facilities—the San Diego air cargo truck deck project illustrates the SilMan difference.

As global logistics continues to evolve, facilities like the San Diego Air Cargo Transfer Terminal become increasingly critical to supply chain efficiency. SilMan Industries remains committed to delivering these transformative projects, combining technical excellence with practical expertise to build the infrastructure that keeps global commerce moving.

Through integrated delivery, proven expertise, and unwavering commitment to client success, SilMan Industries continues to set the standard for industrial infrastructure excellence—one successful project at a time.

About the Company

SilMan Industries (previously SilMan Construction) is based in San Leandro, Calif., with Engineering and Field Operations offices in Tupelo, Miss. The firm provides integrated turnkey solutions in the Industrial, Manufacturing, Distribution, and Public Works sectors.

Notably, in 2010 SilMan Industries was contracted to dismantle and remove the NUMMI assembly line in Fremont, Calif., transport the equipment, and reinstall the system in Blue Spring, Miss., establishing Toyota Motor Manufacturing Mississippi (TMMMS). This high-visibility project ignited the company’s meteoric growth, laying the foundation for SilMan’s national service area.

For more information, please visit www.silmanindustries.com/about.

How does an air cargo transfer terminal manage ULDs between trucks and the airside?

A modern air cargo transfer terminal uses a system of truck decks, heavy-duty scissor lifts, and a caster deck infrastructure. This equipment allows Unit Load Devices (ULDs) to be quickly transferred, weighed, and staged with 360-degree mobility for seamless integration with air operations.

What specialized equipment is essential for a ULD truck deck facility?

Essential equipment includes heavy-duty scissor lifts (like the 10 Southworth Air Cargo Lift units with hydraulic power units installed in the case study) for vertical movement, caster decks for cargo staging and mobility, and precision integrated scales to verify container weights, all supported by a robust electrical distribution system. 

What is the biggest challenge when building a new facility inside an active airport environment (Airside)?

The primary challenge is maintaining operational continuity (zero disruption to cargo flow) while navigating complex security and safety protocols (e.g., SANR designation), multi-tiered permitting processes, and coordinating with multiple airport authority stakeholders.