Transport for London

We have worked on many significant projects for TfL (then known as London Underground Limited (LUL)) since the 1980s, including tube train interiors, external livery, electronic platform signage, public seating, ticket and information booths, ticket machines, entry and exit barriers, help points and safety systems. This culminated in our creation of a comprehensive design manual, providing guidance on the design of LUL’s station hardware.

The results of some of the early work are still in use today, more than 35 years later!

The award-winning Jubilee Line platform screen doors (PSD) have been in service day in and day out since 1999. The introduction of doors on these underground station platforms was a first in the UK and set a precedent for improving passenger safety and comfort.

DCA worked closely with the PSD manufacturer, Westinghouse, to create the design for the Jubilee Line door system. Having previously partnered with them on similar projects for Hong Kong and Singapore metros, we were able to contribute engineering and design solutions for the methods of construction and installation for the Jubilee Line system.

The 1992 Central Line tube trains combine industrial design solutions by DCA, selected through market research and engineered to meet the latest performance and safety standards.

We were employed to exploit the advantages of extruded and welded aluminium bodyshells with a complete re-think and modernisation of the interiors to comply with the latest code of practice on materials selection and fire safety.

Three prototype designs were developed; the red, blue and green trains. Each had its own unique interior and exterior design. We explored ways of making the trains more welcoming, brighter and more colourful.

A market research exercise was carried out to determine the best features of each design which were then combined and integrated into the final 1992 tube stock brief used for the Central Line.

These proprietary emergency detrainment steps were designed and manufactured to the unique requirements for specific rolling stock operating on individual London Underground lines.

DCA undertook the mechanical engineering, usability and Human Factors, prototyping, testing and evaluation, and production support on these safety-critical products. A key aspect was the lightweight, robust design using aviation-grade materials that aligned with low-batch production methods and supported rapid and intuitive deployment by LU staff, including 5th percentile female drivers. It was also vital that the design allowed for the rapid and safe evacuation of a potentially crowded tube train within the challenging time limit set by LU’s operating standards.

The team at DCA designed and built this mock-up at our facilities in Warwick around a steel support frame that provides fixing positions for all the interior and exterior components. The interior is fully finished in fire retardant GRP wall panels and aluminium ceiling panels, with production lighting, handrails and flooring fitted. The exterior is clad in high-quality composite materials with vinyl applied to reflect the Crossrail livery. A bespoke door mechanism was designed and fitted, while the complete mock-up was mounted on a wheeled chassis with integrated braking that allowed it to be manually moved along the tracks at Crossrail’s training centre.