Large airport projects require specialized systems to be procured and coordinated within tight budgets and operating constraints. At San Diego International Airport's New Terminal 1, Turner Construction used early engagement with baggage handling contractors to reduce costs and coordinate a complex system before construction advanced too far to accommodate major changes.
The baggage handling system was required to meet TSA requirements while fitting within a constrained terminal footprint. The scope included in-line screening, RFID tracking and redundant systems designed to support reliable airport operations.
During early design in 2021, Turner developed internal estimates ranging from $105 million to $130 million. Pricing obtained from four major U.S. baggage handling contractors indicated a substantially higher potential market cost, creating pressure to reduce the package without compromising performance or future expansion capabilities.
Turner subsequently involved all four contractors during design development. The team used standardized pricing information to compare proposals, conducted individual industry sessions and sought contractor input on sequencing, site access, laydown requirements and other construction constraints.
The approach allowed constructability issues to be addressed while design options remained flexible.
Turner established a revised target of $105 million as the design progressed. The resulting procurement produced an approximately $85 million base bid and $10 million in selected add-alternates, resulting in a final contract value of about $95 million.
The final amount was approximately $45 million below the initial $140 million market projection and $10 million below Turner's revised target.
During construction, Turner continued coordination among designers and trade partners through 3D BIM coordination, clash detection, field reviews and regular coordination meetings. Commissioning activities were tracked through production targets and real-time dashboards while the team tested nearly four miles of conveyor.
The baggage handling system was completed and placed into service without affecting the New Terminal 1's scheduled opening on Sept. 23, 2025.
During TSA Integrated System Acceptance Testing, the system achieved 99.7% tracking accuracy. Full-system sortation testing also processed 800 bags with near-perfect accuracy.
Turner's project team reported that changes affecting the baggage handling scope were largely avoided. Approximately 85% of identified obstructions were attributed to other building systems rather than the baggage handling installation.
The San Diego airport project demonstrates the cost-control value of bringing specialized trade contractors into design and procurement before major decisions are locked in. For airport owners and construction managers, early market engagement can provide more detailed pricing and constructability information while there is still time to adjust scope and sequencing.
The project also shows how procurement coordination can extend into construction through BIM, field coordination and structured commissioning, particularly for highly integrated airport systems where installation performance directly affects operational readiness.
Source: Turner Construction.
