Turner and FlatironDragados deliver critical infrastructure overhaul amid active airport expansion
April 2026 — Turner Construction Company and FlatironDragados have successfully modernized the Central Utilities Plant (CUP) at San Diego International Airport, while keeping the airport fully operational.
The upgrade forms a key part of the airport’s Terminal 1 replacement program, one of the largest ongoing airport construction projects in the United States.
Challenge: Upgrading critical infrastructure without shutdowns
The Central Utilities Plant, originally built in 1995, required a major upgrade.
The expansion created new demand, including:
- 5,000 tons of additional cooling
- 26 MMBH of heating capacity
However, the existing system lacked the capacity and efficiency to support this growth.
At the same time, the plant had to remain operational throughout construction.
In addition, tight site conditions near active airport facilities increased complexity.
Solution: Modernization over replacement
Instead of building a second plant, the team chose to upgrade the existing facility.
This decision reduced costs and simplified long-term operations.
Key upgrades included:
- Replacing old chillers with higher-capacity units
- Adding a heat recovery chiller and buffer tanks
- Expanding cooling towers
- Installing high-efficiency boilers
- Upgrading pumps and control systems
Moreover, seven variable frequency drives improved energy efficiency and system control.
Minimizing disruption through smart execution
The project team used phased construction to maintain operations.
For example:
- Only two chillers were taken offline at a time
- Shutdowns were limited to short overnight windows
In addition, ACCO Mechanical prefabricated piping offsite to speed up installation.
Crews also installed a half-mile hydronic system connecting the plant to the new terminal.
They completed deep underground work, including road crossings, without interrupting traffic.
Results: Early delivery and uninterrupted service
The upgraded plant was completed four months ahead of schedule.
As a result, teams had extra time for testing and commissioning.
Importantly, airport operations continued without major disruptions.
Passengers experienced no service interruptions during construction.
Enhanced capacity and long-term efficiency
The modernized plant now delivers:
- 5,000 tons of cooling
- 26 MMBH of heating
It also features improved efficiency, redundancy, and advanced controls.
Therefore, the airport is better equipped to handle future growth.
Part of a larger airport transformation
The CUP upgrade supports the broader Terminal 1 redevelopment project.
Phase 1A is complete and includes 19 new gates.
Phase 1B is now underway and will replace the old terminal.
Once finished, Terminals 1 and 2 will connect post-security, improving passenger flow.
The full project is expected to be completed in 2027.
Outlook
This project highlights how complex infrastructure upgrades can proceed without disrupting operations.
It also demonstrates the value of phased construction and prefabrication in large-scale projects.
