Summary
Ball decks keep global air freight moving. Learn how ball transfer units load, position and weigh ULDs at cargo terminals, on dollies and in aircraft holds.
Ball transfer units are essential components in air cargo handling, arranged in arrays called ball decks that let operators load, unload, position and weigh Unit Load Devices (ULDs) with precision and minimal effort. Ball decks are found in aircraft holds, at cargo terminals, on weighing stations and on dollies. Alwayse has supplied heavy-duty ball transfer units — rated up to 12,000kg — to the air cargo industry for decades, exporting to more than 75 countries.
The global air cargo industry moves over 60 million tonnes of freight a year, and almost every item passes over ball transfer units somewhere in its journey. From a container being built up at a warehouse to its final position inside an aircraft, ball decks provide the low-friction, omnidirectional movement that makes modern air freight possible. Explore the standard ball decks and the air cargo and logistics sector.
What is a ball deck?
A ball deck is a flat surface embedded with an array of ball transfer units. The balls sit slightly proud of the surface, creating a low-friction platform over which heavy items — ULD containers and pallets — can be pushed, pulled and guided in any direction by hand or with minimal mechanical assistance. Purpose-built for aviation, ball decks are engineered for heavy loads, demanding duty cycles and strict safety requirements, typically in steel or aluminium with heavy-load units.
Where ball transfer units are used in air cargo
Aircraft cargo holds
Inside aircraft compartments, ball transfer units are integrated into the floor so ULDs can be rolled into position during loading and secured for flight. Omnidirectional movement lets ground handlers guide containers precisely into place, even in the confined space of a hold.
Cargo terminal workstations
At terminals and handling centres, ball decks act as transfer platforms where ULDs move between build-up, storage and the dolly that takes them to the aircraft. A single operator can reposition containers weighing several tonnes.
Cargo weighing stations
Air cargo floor scales use ball decks with integrated weighing systems. The units let ULDs roll smoothly on and off the scale, speeding weighing and preventing damage. Accurate weight is critical in aviation — overloaded aircraft are a serious safety risk — so ball-deck scales make the process fast, safe and reliable. Alwayse has delivered exactly this solution; see the Bogotá airport case study.
Truck and dolly loading
Ball transfer units are also fitted to dollies and truck beds used to move ULDs between terminal and aircraft, letting containers roll on and off without cranes or forklifts and cutting turnaround time.
Why ball transfer units are critical in air cargo
- Speed — every minute on the ground is lost revenue; ball decks enable rapid, precise loading without waiting for powered equipment.
- Safety — they cut the physical effort of moving heavy cargo to a fraction, reducing musculoskeletal injury, one of the biggest risks in logistics.
- Precision — omnidirectional movement allows the fine positioning needed to meet aircraft weight-and-balance requirements.
- Cargo protection — smooth, controlled movement minimises the jolts and impacts that damage high-value freight.
Specifying ball transfer units for air cargo
Air cargo places demanding requirements on every unit. Load capacity must cover ULDs of several tonnes — heavy-duty units rated 500kg or more per unit are typical, with total deck capacity engineered to the maximum load plus a safety margin. Durability must withstand near-continuous use; precision recirculating-ball designs last longest. Corrosion resistance matters where decks meet weather, jet fuel and de-icing fluid, so stainless or coated units are common. And low friction is the whole point — specify the lowest practical friction so operators move heavy loads with ease.
Alwayse and air cargo
Alwayse has supplied the air cargo industry for decades, with a heavy-duty range engineered for aviation logistics and the ability to design bespoke ball deck systems — from weighing-station decks to modular terminal fit-outs. To discuss a requirement, contact the team on +44 (0)121 380 4700 or sales@alwayse.co.uk.
Frequently asked questions
What is a ball deck in air cargo?
A ball deck is a flat platform embedded with an array of ball transfer units, designed for aviation. It lets ULDs and cargo containers be moved smoothly in any direction with minimal effort, and is used in aircraft holds, at terminals, on weighing stations and on dollies.
Why are ball transfer units used instead of rollers in air cargo?
Ball transfer units move cargo in any direction, including sideways and diagonally, while rollers only move along one axis. In the confined space of a hold or terminal, where containers must be positioned precisely, that omnidirectional flexibility is essential.
How heavy are the loads handled by air cargo ball decks?
Loaded ULDs can weigh several tonnes. Ball deck systems use heavy-duty units to handle these weights safely, with individual unit capacities typically from 500kg to over 2,000kg, and Alwayse solutions scaling to 12,000kg.
Can ball decks be used outdoors?
Yes. Decks on airport aprons and outdoor cargo areas are built with stainless or corrosion-resistant units to withstand weather, jet fuel, de-icing chemicals and other environmental exposure.