• Nippon Steel & Sumikin Engineering Co., Ltd.

    Tokyo International Airport Re-expansion Project

    Tokyo, Japan

Project Summary

The JPY 600 billion D-runway at Tokyo International Airport will accommodate growing demand and provide additional arrival and departure slots. With limited space, the only option was to build into the sea on an island 3,120 meters long with a 1,100-meter-long steel jacket-type pier. Nippon Steel & Sumikin Engineering performed detailed design in just 18 months and led the five-year construction phase for the jacket structure, which is the first of its kind to be used in airport infrastructure.

The jacket structure is 520 meters wide, has an area of 520,000 square meters, and comprises 198 separate units. SACS was used to conduct the complex fatigue analyses for the jacket units – totaling nearly 40,000 checkpoints – in just six months. Automatic calculation of stress concentration factors shortened the time required, and material take-offs allowed quantity estimates to be made immediately upon completion.

The new D-runway has augmented airport capacity by 111,000 annual arrival and departure slots. The maximum assumed load in the design equals an Airbus A380 with a maximum takeoff weight of 400 tons, travelling over the pier 11.5 million times during the life span of this structure. The live-load to dead-load ratio significantly exceeds that of general highway bridges and the extremely high fatigue strength, designed into the structure, ensures the runway will last for over a 100 years.

If Nippon Steel & Sumikin Engineering had not used SACS to evaluate fatigue points, it would have been necessary to develop a new application rather than increase the required manpower. At an estimated cost of JPY 5 million and two months of software development time, an in-house application would have been too costly and time-consuming. Selecting SACS successfully saved time and money on the project.
  • The pier is designed to withstand an Airbus 380 aircraft traveling over it 11.5 million times in its 100 year life.
  • SACS saved an estimated two months on the analysis, and an additional JPY 5 million compared to developing an in-house fatigue analysis application.
  • Nippon Steel & Sumikin Engineering carried out detailed design of the jacket-type pier structure in just 18 months.