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Voice of Users

Construction Industry IT System

Tokyo International Airport Runway D Construction

Construction Industry IT Utilized in New Runway Construction
TOUGHBOOK supports Quicker Construction and Rigorous Quality Control

To the south of Tokyo International Airport, on land reclaimed from the sea, work is progressing on Runway D, the airport’s fourth runway. A consortium of 15 companies is working round the clock to finish the runway, which is scheduled to open less than a year from now, in October 2010. To speed up construction and ensure quality, construction industry IT is being applied at the eastern end of the runway, a zone in which PENTA-OCEAN CONSTRUCTION CO., LTD., TAISEI CORPORATION, and MAEDA CORPORATION are responsible for seawall construction and reclamation work. TOUGHBOOK PCs, designed for the rigors of construction sites, have been adopted to avoid the problems caused by computer breakdowns and achieve smooth progress.

TOUGHBOOK supports Construction Industry IT

Along the 2,500 m length of Runway D, a section of 2,020 m by 424 m is on reclaimed land and pier on a 1,100 m by 525 m section edged with a wharf. At the start of November 2009, heavy equipment was deployed to begin reclamation work. The site was crisscrossed with the comings and goings of giant dump trucks, bulldozers, vibratory rollers and other construction vehicles. Less than a year later, in October 2010, the new runway is scheduled to open for takeoffs and landings. To achieve such early completion, it was necessary to introduce Construction Industry IT and use computers to support the work of the heavy equipment.

The construction consortium involved in Tokyo International Airport Re-expansion (Runway D) Seawall and Reclamation Zone (I) is responsible for about 500 m of the easternmost end of the runway. Section Leader of the Penta-Ocean Construction Technical Research Center Construction IT Team, Mr. Hitoshi Ishida, who provides onsite support for the IT construction, commented, “If we hadn’t introduced construction Industry IT, it would have been unreasonable to expect the work to proceed so rapidly.”

A crucial factor in land reclamation is how fast the soil can be firmly compacted. Bulldozers spread 60 to 90 cm layers of earth, each of which is then compacted eight times by 35-ton vibratory rollers.”

In this construction zone, all of the two 38-ton and one 27-ton bulldozers, four 35-ton vibratory rollers, and a completed-work survey vehicle are fitted with TOUGHBOOK CF-19 PCs, the leading computer for use on construction sites. The CF-19 helps both to improve work efficiency and to ensure high quality construction.

TOUGHBOOK installed alongside the dashboard of heavy equipment

TOUGHBOOK installed alongside the dashboard of heavy equipment working on the construction of Tokyo International Airport Runway D.

In the construction zone at the easternmost end of Runway D

In the construction zone at the easternmost end of Runway D, while achieving construction quality, TOUGHBOOK PC-equipped vehicles have been getting the work done more quickly.

TOUGHBOOK CF-19

TOUGHBOOK CF-19
The CF-19 is a compact TOUGHBOOK with a 10.4-inch monitor. In tablet mode, it is suitable for a wide range of applications, including handheld operation or mounted in a vehicle. The touch screen can be operated with a stylus or even with gloved fingers.

Elevation data displayed to operators

The role of the TOUGHBOOK PCs installed in the cabs of bulldozers is to help achieve uniform soil-spreading thickness by providing the operator with accurate data. To the lower right of the driving seat is arranged a line of red and green LED indicator lights. They show, in 5 cm units, how much the surface deviates from the planned elevation. This enables the operator to monitor current elevation while watching the surface conditions at the bulldozer blade.

Mr. Ishida explained, “Data for the planned elevation of coordinates on the artificial island are entered into the TOUGHBOOK. This is compared with data for the current location, which is acquired through the bulldozer GPS receiver. If the actual ground level differs from the planned elevation, the amount of difference is immediately apparent from the LED indicator status.”

Without this equipment, to guide construction all across this vast site, it would be necessary to use surveying equipment to stake out the terrain and set up innumerable temporary signs showing location, elevation, and incline. And during the hours of darkness, it would be almost impossible to reliably work according to the stakes. The use of computer-equipped bulldozers is delivering the promise of rapid construction of Runway D.

The TOUGHBOOK is installed behind the driver’s seat.

The TOUGHBOOK is installed behind the driver’s seat.

A line of LEDs shows the operator when the current ground level differs from the planned surface elevation.

Mounted to the right of the bulldozer dashboard, a line of LEDs shows the operator when the current ground level differs from the planned surface elevation.

Across this vast reclamation site, bulldozers spread earth and sand in layers of even thickness.

Across this vast reclamation site, bulldozers spread earth and sand in layers of even thickness.

Adequate compaction assured: complete quality control

One of the quality control criteria for vibratory roller ground compaction is for the roller to pass exactly eight times over each place. Installed in the vibratory roller at the driver’s seat, the TOUGHBOOK performs the duty of recording the number of passes over each spot. Even on a vast site that is not staked out, inadequate compaction can be avoided because the operator can clearly see onscreen how many passes have been made.

The screen of the TOUGHBOOK, mounted to the right of the dashboard in the cab, displays a ground plan of the current construction area. The passes made by the vibratory roller are represented by strips on a ground plan displayed on the screen and these strips change from light blue to green to orange in accordance with the number of passes made. Then, when the entire ground plan of the current construction area is blue all over, the color showing that eight passes have been made, compaction is complete.

If any patches of the vast area of land reclamation have not received a full eight passes, it is clearly obvious because they remain displayed on the screen in a color other than blue. Mr. Ishida says, “If we didn’t have this kind of system, on a vast construction site, there would be no way of strictly counting the number of roller passes.”

Another type of vehicle is also fitted with a TOUGHBOOK: the completed-work survey vehicle is equipped to measure the features of the current ground surface and, at any time, can carry out accurate assessment of the terrain. In the early stages of reclamation, the subsidence of new land is likely to occur. To check for this, the ground is surveyed at various times, such as before construction starts and at fixed intervals after compaction has been done.

The completed-work survey vehicle records the current elevation of the ground.

The completed-work survey vehicle records the current elevation of the ground.

Mounted on the passenger seat, the TOUGHBOOK shows the survey results.

Mounted on the passenger seat, the TOUGHBOOK shows the survey results.

A 35 ton vibratory roller working to firmly compact this vast reclamation site.

A 35 ton vibratory roller working to firmly compact this vast reclamation site.

A TOUGHBOOK mounted at the driver’s seat in a vibratory roller.

A TOUGHBOOK mounted at the driver’s seat in a vibratory roller. Onscreen, you can see a ground plan of the current construction area with strips colored according to the number of compactions the ground has received. Adequate compaction is assured.

Continues operating even through 8G shocks in the driver’s seat

The construction industry IT system used on this site and incorporating the TOUGHBOOK follows on from a prototype system, developed by PENTA-OCEAN CONSTRUCTION CO., LTD. during 2002 to 2003. While engaged on second-phase construction at Kansai International Airport, the company simultaneously developed working systems for bulldozers and vibratory rollers.

Mr. Ishida commented, “For construction industry IT systems, performance demands and mode of use needs are different for different sites. That’s why we developed an adaptable system that could be improved according to site conditions and operator need.” To ensure easy maintenance, for the current construction industry IT system, the only type of computer that the company installed in its construction vehicles was the TOUGHBOOK CF-19.

The compact custom-built metal cases for mounting the TOUGHBOOK CF-19 PCs in the cabs of bulldozers and vibratory rollers were specially produced by the company. Mr. Ishida explained, “Measurements have been made of the kinds of acceleration undergone by the bodies of vibratory rollers. When carrying out work, vibration and impact may reach 6 or even 8G. Such harsh conditions would soon cause breakdowns in an ordinary computer. We could only fit out our vehicles because there are computers like the TOUGHBOOK, which are suitable for use on construction sites.”

It was at the end of March 2007 when work started on the site. At that time, the site was still under the sea. Now it is an island rising 10 m above sea level. When Runway D is completed, the new capacity it gives to Tokyo International Airport is likely to consolidate its ability to act as an Asian hub airport. In the face of international competition from other airports, the TOUGHBOOK has played an essential role in rapidly increasing the capabilities of Tokyo International Airport.

 

TOUGHBOOK installed at the driver’s seat of a vibratory roller, which can receive 6 to 8G acceleration.

TOUGHBOOK installed at the driver’s seat of a vibratory roller, which can receive 6 to 8G acceleration. Customized, specially designed metal fittings hold the computer firmly in place.

Mr. Ishida (left) getting operator feedback about the current state of work.

Mr. Ishida (left) getting operator feedback about the current state of work.

Customers
PENTA-OCEAN CONSTRUCTION CO., LTD.
TAISEI CORPORATION
MAEDA CORPORATION
Tokyo International Airport Runway D Construction 

http://www.haneda-d.jp/
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