Stainless Steel Bus Bodies :

Cost Less & Last Long

 Indian Stainless Steel Development
Association
(ISSDA)
• Not for profit organization.
• Technical and market development arm of the
stainless steel industry in India.
• Aim is to educate engineers, architects and
material specifiers in the end use sectors and
diversify the applications of stainless steel.
 Indian Stainless Steel Development
Association
(ISSDA)
• Organises workshops, seminars and conferences.
• Technical information service.
• ISSDA is networked with all stainless steel
development associations of the world
• Newsletters, Brochures.
• www.stainlessindia.org
How stainless steel works
Steel
+
Steel > 10-12% Chromium

Passive Film
Rust

Carbon
Steel Stainless
Steel Steel

The corrosion resistance of stainless steel

comes from the chromium-rich passive layer
 STAINLESS STEEL: Cr-Oxide Layer

Passive Film

Stainless Steel Surface Damage Self Repairing

SELF REPAIRING SURFACE

 India vis-à-vis World
2012
2000s

Early 1990s

1980’s

1940s

Fig: Per capita penetration : Buses per 1000 person

Source of info : INSAPTRANS handbook
 Advantage of Stainless Steel

• Low Maintenance cost • Crash Resistance

• Ease of cleaning • Fire resistance
• Ease of repair
• No painting required
• Aesthetics
Lower
Safety
maintenance

Lower life
Design cycle cost /
Longer life
• Lower tare wt • High paybacks
• High Strength to wt ratio • Fuel efficiency
• Higher payload • Lesser corrosion
• High axle load • Lesser wear of floor
7
 Train crash in Australia at 80 kmph.
Stainless steel saves lives !

Bus accidents 42,600 (in 2009)

Causalities Approx 13,000 people Crush Behavior of stainless steel circular
hollow section maximizes energy absorption
Injuries 58,000 in the event of a collision (Euro Inox 2006a)
Source: Report on “Road accidents in India 2009”, Ministry
of road transport and highways
 In the case of fire, the structural integrity of a stainless steel body
remains intact much longer than that of carbon steel body and longer
still that of an aluminium body.
 Low thermal conductivity of stainless steel tends to retard the spread
of heat damage to structural components.
 No paint, No hazard

Variation of Young’s Modulus with Temperature for

Stainless Steel and Carbon steel

Source of info : ISSDA/NiDi architectural

workshop April 2001
 SS

View of Stainless steel framework

underneath bus. Approximately 10
years old

Severe corrosion of a mild steel

bus structure
 Technically, stainless steel is superior to mild steel

• Strength+Ductility
Corrosion • Function of Cr content
• SS with higher strength and Toughness
comparable ductility is a better
resistance • SS with high Cr content is
option much better than MS

SS

• Fully recyclable
vs. • Fatigue strength of SS is
better than MS
MS
Green
Material Fatigue resistance
Global References /
Case Studies
Greyhound: United Kingdom

In 1968, Greyhound introduced its improved MCI-7 model

using stainless steel in the chassis with stainless steel skins
to address the rust problem.
 Greyhound: United Kingdom

The model MCI 8 came next from 1973 to 1978. 4,475 units were
built and it was squarer and more modern looking than the MCI-7
with more stainless steel in the sub chassis.
 Greyhound: United Kingdom

Fig: MCI-9, a high mileage low maintenance intercity long haul over-the-road coach

Between 1979 to 1987 came the now famous MCI-9 model and it’s
still being manufactured (as the MCI 12). The most successful
Passenger Bus ever made, with over 9,000 have been produced.
This coach's sub-frame and the rear section around the engine is
90% Stainless Steel.
 Case Study: Volvo, Finland
 Since 1991, Volvo (Finland) is fabricating bus coaches for its 9700 model in
Stainless Steel for its two and three-axle coaches.
 Coach Length: 10.4 -15 metres in length.
 Both underframe and body are stainless steel, to ensure a long life.

Fig: A three-axle Volvo 9700 in at the IAA exhibition in Hannover in 2006 (Geoff Stephenson)
 Case Study: Volvo, Finland
“This body construction is chosen to give the
customer the advantages of a corrosion-resistant
framework. Bus which is made of stainless
steel retains an attractive appearance for the whole
of its life, reduces maintenance and service costs and
ensures a high second-hand value.” – Volvo (Finland)
 Europe: SS in Bus Body

Figure: Articulated bus with a skin in

ferritic stainless Steel (Van Hool 2007).

 European bus manufacturers started using stainless steel in the early 1990s.
 Development started specifically in Scandinavia, where a cold and humid climate, often
involving the use of de-icing salts, explains operators’ willingness to consider a corrosion-
resistant material such as stainless steel.
 According to 2008 data, 80% of the buses in Europe are in stainless Steel.
 The buses are lighter with improved crash worthiness of the passenger compartment, require
less maintenance, and are more fuel-efficient.
 Case Study: Volvo, Australia
 Australia’s first stainless steel buses were
manufactured by Bus Tech Pty. Ltd.

 These buses were made for Volvo, Australia.

 The interior & exterior panel along with the

tubular structure was made in stainless steel

15%
700 kg
reduction in Life period up
SS body shell reduction in
production to 15 years
tare wt.
time

• 200 m of square hollow sections

• Savings of $2 per km in petrol cost
• 600 kg of SS sheet
• Can Carry additional passengers
• Finish : 2B

ASSDA initiative – Bus Tech Pvt. Ltd for Volvo, Australia

 Case Study: Silver Eagle, USA

 Silver Eagle Bus offers buses in a stainless steel chassis & stainless steel skins
 It utilizes Stainless Steel panels for designing the bus bodies.
 The features also include Stainless Steel Chassis Up to Floor Line Standard.
Autokinetics, Inc.
(Ultra light stainless steel urban bus concept)
Recent developments in SS bus body frame show tremendous potential
Case study :
Results
Methods
Goals • Mass reduction
• Nitronic 30 grade SS
• Mass reduction • 64% redn wrt
• UTS – 827 Mpa
• Minimise cost conventional bus
• High elongation % • lower curb wt – 42%
• purchase
• High fatigue strength increase in payload within
• operation legal axle limits
• Forming process
•life cycle • Cost reduction
• contour roll forming
• Improved performance, • cost of Nitronic 30 less
• Joining process – spot than 304
usability & comfort
welding • Higher yield for roll
forming process
• low tooling investment
 SS Success Story: Railway Coaches

Courtesy: RCF, Kapurthala

 SS Success Story: Railway Coaches

Courtesy: RCF, Kapurthala

SS Success Story: Metro
Bus Body: Indian Initiatives
 Indian Initiatives
Developments at Shillibear, Kerala

SS Bus Panel

Footsteps in SS cheq sheets

Indian Initiatives
Developments at Shillibear, Kerala

Floors in SS cheq sheets

Floors in SS cheq sheets

Case Study: TNSTC-Coimbatore
 TNSTC-Coimbatore introduced many stainless steel body city buses in its
Coimbatore, Erode and Tirupur regions.

 SS body city buses have been launched with the name “City Express”.
 Where Stainless
Steel can be used
Tubular Structure
 Properties required for Structural
 High Strength to weight ratio – Lighter coach
 Toughness – Formability & Crash resistance
 Corrosion resistance – Longer Life
 Fatigue resistance - Longer Life
 In case of fire – Structural Integrity
 No Paint – Passenger safety, Environment friendly
Structural members: Current Material
Carbon Steel : IS 4923 of 1997,
Grade: YST 210

Square Tubes Rectangular Tubes Properties Value

(popular sizes) (popular sizes)
25 X 25 60 X 40 YS 210 MPa min
40 X 40 75 X 50 UTS 330 MPa min
50 X 50 20 X 50 Elongation 20% min
25 X 50

Source of info : Discussions with Ashok Leyland / Swaraj Mazda/Shillibear

 Tubular Structure
YST 210
• Typical Y.S : 210 Mpa
Weight reduction
with SS is ~ 20%

Stainless Steel
• Typical Y.S : 280-320 Mpa
 Panels

SS stretch panel

SS skirt panel
 Properties required for Panels
 Resistance to corrosion
 Resistance to vibration (drumming resistance)
 Function of Panel Stiffness
 Stiffness is ability of material to resist bending
 Stiffness = Young’s Modulus

 Aesthetic Value
 Crash worthiness: SS bears very high impact
resistance that makes it a safer material in case of
accidents.
 Panels: Current Material
AL Alloy

Consumption in 12 m long bus: approx. 300 to 400 kg

Young’s Modulus: 74 GPa

Panel Thickness Length Width

Side Panel – Top 2.5/3.0 mm 20 m 850 mm

Side Panel – Bottom 2.5/3.0 mm 20 m 1200 mm

Source of info : Ashok Leyland / Swaraj Mazda / JCBL

 Panels: Stainless Steel

 Stainless steel
 Young’s Modulus
: 205 GPa

 Based on Young’s Modulus comparison,

– 1.00 – 1.5 mm thick SS grades can be used
Footsteps & Flooring
 Floorings: Current Material

Current Material: Al cheq plate

Thickness: 3.0 – 3.5 mm
Stainless Steel : 0.8 to 1 mm
 SS chequered plates
Advantages
 Yield Strength : High - 515 MPa
 Hardness : High – Vickers 275
 Wear & Tear behaviour : Low due to high rigidity and hardness
 Fixing method : Assembly with screws, rivets and welding
 Weldability : Good
 Cleanability : Easy
 Expected life : High
 Relief : Double side (as compared to mild steel’s single side relief)
 Corrosion resistance : High

Applications:
 Floorings
Foot steps
 Entrance
 Luggage Carrier
SS chequered plate
Other Applications

Roof Panels in SS
Other Applications

Back Support Frame

Seat Underframe
 Other Applications

Guarding of Step wells

Hand Rails and Hand Holds

Fasteners
 Life cycle cost Comparison

Rebuilding
3,28,000
SS Body Initial Cost

Overhaul
2,80,000
Up to 15 yrs
Cost (Rs)

1,64,000
MS Body Initial Cost

Fuel saving on SS body

0 2.2 4 6 8
Time in years Cost of the entire bus is
recovered.
LCC = Acquisition cost+ Fabrication &
installation cost+ Maint.cost (Periodic) +
Replacement costs (Periodic) + Cost of
downtime (periodic) + Residual (scrap)
value
LCC
The Taj Mahal would not have been so beautiful if Shah Jehan had asked for
quotations and gone for the lowest.
Thank You
 Fabrication of Super Luxury Bus Body with Stainless Steel Grade-1.4003 Material - Costing Analysis
MILD STEEL STAINLESS STEEL 1.4003 Cost
Proposed
S.No Description UT Qty Rate Amount Qty Amount Difference Landed cost of SS sheet
thickness
1 ALU.SHEET 3.00 MM KG 18.05 146.86 2650.823 1.0 MM 17.12 1712.15 938.67 Sheet price (basic, ex-Hisar) 86000 Rs/MT
2 ALU.SHEET 2.00 MM KG 50.80 146.86 7460.488 1.0 MM 72.65 7265.09 195.40 Add : Excise+cess @ 10.3% 8858 Rs/MT
3 ALU.SHEET 1.6 MM KG 53.88 146.86 7912.8168 1 MM 96.31 9631.08 -1718.26 Sub-total 94858 Rs/MT
Total 122.73 18024.128 186.08 18608.32 -584.19 Add : CST @ 2% 1897 Rs/MT
Sub-total 96755 Rs/MT
4 MSL 25x25x3 MM KG 24.25 36.00 872.856 2MM 16.16 1616.40 -743.54 Add : freight 3000 Rs/MT
5 MSL 40X40X3 MM KG 139.27 36.50 5083.428 2MM 92.85 9284.80 -4201.37 Total landed at A.P. 99755 Rs/MT
6 MSL 40X40X6 MM KG 225.24 35.00 7883.4 4MM 150.16 15016.00 -7132.60
7 MSL 50X50X6 mm KG 26.42 35.00 924.7 4MM 17.61 1761.33 -836.63 Landed cost of SS tubes
8 SAIL 100x50 CHANEL KG 318.03 36.00 11449.152 4MM 212.02 21202.13 -9752.98 Tube price (basic, ex-Gurgaon) 102000 Rs/MT

9 SAIL -75X40X6 CHANNEL KG 36.00 4112.1 4MM 76.15 7615.00 -3502.90 Add : Excise + cess @ 10.3% 10506 Rs/MT
114.23
10 GI SHEET 0.91 MM KG 499.22 48.00 23962.416 0.80MM 443.75 44374.84 -20412.43 Sub-total 112506 Rs/MT
11 G.I.SHEET 0.91 MM SKINPASS KG 110.09 49.00 5394.557 0.80MM 97.86 9786.04 -4391.49 Add : CST @ 2% 2250 Rs/MT
12 MS PLATE 6MM KG 79.40 40.00 3176.04 4MM 52.93 5293.40 -2117.36 Sub-total 114756 Rs/MT
13 MS SHEET 0.91MM KG 43.93 45.00 1976.805 0.80MM 39.05 3904.80 -1928.00 Add : Freight 3000 Rs/MT
14 MS SHEET 1.22 MM KG 47.73 45.00 2147.67 0.80MM 31.30 3129.57 -981.90 Total landed at AP 117756 Rs/MT
15 MS SHEET 1.6 MM KG 46.39 45.00 2087.64 1MM 29.00 2899.50 -811.86
16 MS SHEET 2 MM KG 331.78 45.00 14930.1 1.6 MM 265.42 26542.40 -11612.30
17 MS SHEET 3.15 MM KG 111.61 42.00 4687.62 2.5 MM 88.58 8857.94 -4170.32
18 ERW PIPE 25X2 O/D KG 38.50 42.38 1631.52 1.6 MM 30.80 3634.40 -2002.88
19 M.S.SQ.TU.25X25X2 KG 14.10 56.06 790.38 1.6 MM 11.28 1331.04 -540.66
20 M.S RECT.TU.40X20X2 KG 195.00 56.32 10983 1.6 MM 156.00 18408.00 -7425.00
21 M.S RECT.TU.40X30X2 KG 33.87 56.93 1928.36 1.6 MM 27.10 3197.33 -1268.97
22 M.S.SQ.TU.40X40X2 KG 288.57 58.24 16806 1.6 MM 230.86 27241.01 -10435.01
23 M.S.REC.TU. 60X40X2 KG 411.75 54.46 22422.18 1.6 MM 329.40 38869.20 -16447.02
24 MS ROD 6 mm DIA KG 0.48 35.96 17.2608 0.48 17.26 0.00
25 MS ROD 8MM SIDE KG 2.31 36.00 83.052 2.31 83.05 0.00
26 MS ROD 16MM SIDE KG 1.57 36.00 56.628 1.57 56.63 0.00
27 MS ROD 25 MM SIDE KG 0.91 36.00 32.76 0.91 32.76 0.00
28 MS FLAT 25X3 mm KG 9.40 36.00 338.472 9.40 940.20 -601.73
29 MS FLAT 25X6MM KG 7.52 36.00 270.54 7.52 751.50 -480.96
30 MS FLAT 40X6 MM KG 41.49 36.00 1493.568 4 MM 27.66 2765.87 -1272.30
31 MS FLAT 50X6 MM KG 2.27 36.00 81.864 4 MM 1.52 151.60 -69.74
32 Total 3288.05 163648.2 2635.72 277372.32 -113724.13
33 DIFF KG 652.33
Additional cost towards SS material 113724
Additional cost towards forming & cutting SS material 10000
Less cost of hotphosphating & epoxy primer of mild steel -11334
Total 112390
Weight reduction with SS 652.33 kg 20%
Savings on fuel : 2litres per 100 km of travel per 1000 kg wt redn.
ie fuel savings per km of travel per 1000 kg wt reduction 0.8 (considering diesel price as Rs 40/litre)
For the net wt reduction, fuel savings per km travel 0.52 Rs/km
Minimum distance traversed by bus per annum 100000 km/year
Thus, total fuel savings per annum 52186.68176 Rs/annum
Thus, the incremental cost of Rs 1,12,000 with SS can be recovered 2.2 years
Life of MS bus is 4 years, after which the entire body is changed.
Life of SS bus would be minimum 8-10 years.
Total cost of MS bus
a. Material cost with MS 163648.1966 Rs/bus
b. Cost of hot phosphating & epoxy primer 11334 Rs/bus
Thus, total RM+Hot phosphating cost of MS bus 174982 Rs/bus
Thus, total cost of MS bus over a period of 8 years 349964.3932 Rs/bus
Total cost of SS bus over 8 years 123724 Rs/bus
Thus, cost benefit with SS bus over MS bus 226240 Rs/bus
Fuel savings of SS bus over 8 years 417493.4541 Rs/bus
Thus, net savings with SS bus (I62+I63) 643734 Rs/bus