How bus design constraints vary across the globe

That’s an extreme scenario, but designing a bus that can operate anywhere in the world is a challenge. In Western Europe, an average height bus driver might be almost half a foot taller than one in Southeast Asia, according to a WorldData summary of 2,000 studies on human height. That’s a significant difference, but driver height is just one of many considerations that go into designing buses that suit the local environment, according to Roger Brereton at bus steering systems manufacturer Pailton Engineering.

After all, tight, winding European city puts different demands on a vehicle than a long, straight North American highway. In the same way, a dusty rural route in India puts very different stresses on components compared with a cold, heavily salted winter road in Scandinavia or Canada. Here, Brereton looks at some of the ways bus design varies around the world.

Environmental differences

One of the first things to consider when designing buses for international roads is the environment they will be working in. Humidity and salt-laden air, whether from tropical coastlines or winter gritting, can corrode metal components. Meanwhile, dust and sand, common on rural or desert routes, can work their way into bearings and joints, shortening service life and increasing maintenance costs.

For steering components, getting around these environmental hurdles requires careful material selection, with corrosion-resistant coatings and seals designed to keep contaminants out. For example, a bevel box destined for a tropical city like Medellín might use high-temperature-resistant grease in the bearings, rubber boots designed to resist cracking in heat, and a higher ingress protection rating to protect against heavy rainfall and persistent humidity. 

But a bevel box specified for a bus in Alaska might instead prioritise anti-corrosion coatings to resist road salt, and grease formulated to keep performing in sub-zero temperatures. Additionally, in rural areas where opportunities for routine maintenance or spare parts might be limited, designers might choose maintenance-free components that last the lifetime of the bus.

Local infrastructure

Next, the bus must also suit local street layouts. In dense historic cities, drivers need a tight turning circle and responsive steering, whereas in regions with long highways, stability at speed is more important. Rural or developing regions might require higher ground clearance and reinforced suspension for poor roads, while urban centres with narrow streets, steep gradients, or low bridges might create dimensional constraints and require more compact designs.

Local infrastructure could also determine powertrain choice. In some markets, diesel is still the go-to fuel, but many cities are transitioning to battery-electric or alternative fuels like hydrogen. Local grid capacity, charging or fuelling infrastructure, and energy costs will heavily influence the viable options. E-buses might also have different design needs, such as parts that can handle the additional weight of the batteries.

Workstation adjustability

Finally, as our Dutchman from earlier found out, in some countries, the average driver might be as much as a foot taller or shorter than in others. This affects the ergonomics of the bus driver workstation. For instance, the height or tilt of the steering column and the position of the controls might not be right, causing significant discomfort over an eight-hour shift. Choosing a fully adjustable steering column would help all drivers, no matter where they come from.

Wherever your bus will be operating, working with a parts supplier that can adapt to changing requirements will help. The right design makes the driver’s job easier, safer, and less fatiguing, wherever they are in the world.