Supply of Escalator Steps (Fabricated and Die-Cast)

In the last decades the vast majority of the world of escalator steps production has been migrating to die casting. TfL's present die-cast step fleet is at 43%. The introduction of die-cast steps has been primarily through our main escalator contractors during escalator replacement or refurbishment works. TfL are looking to accelerate the percentage of the step fleet which is die-cast by proactively replacing fabricated steps on our internally maintained legacy fleet with interchangeable die-cast steps.

The MH-B step is deemed to be the most appropriate candidate to begin the conversion: today more than 18,000 MH-B steps are installed in MH-B, MY-A, and MH-A Otis escalators. Their replacement is intended to contribute by 21% to the whole fleet conversion.

The scope of the contract is summarised below:

1. Desktop study

a. Design of Escalator Steps to meet specification

b. Finite Element Analysis (FEA) of step to meet load cases in specs

c. Feasibility of mould design to verify that the step geometry be achieved within constraints of moulding technology available

2. Die Cast Moulding

a. Mould Design

b. Manufacture of mould

c. Prototype testing and quality assurance against BS EN 115 and SPC-LAE-421479903

3. Manufacturing of Escalator Steps

a. Ability to die-cast steps

b. Minimum production runs per order

c. Number of shots for life of mould

4. Delivery and Storage of Escalator Step

a. Typical lead time

b. UK storage

A first study for the new die cast design has been performed (drawing 564-12031 Rev.A) and the set of requirements for the step supply has been collected in the SPC-LAE-421479903.

The Contractor will be asked to follow the SPC document as a technical reference.