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Major cause of air pollution in the world is due to burning of fossil fuels for transport application; around 23% GHG emissions are produced due to transport sector. Likewise, the major cause of air pollution in Indian cities is also due to transport sector. Marginal improvement in the fuel economy provide profound impact on surrounding air quality and lightweighting of vehicle mass is the key factor in improving fuel economy. The paper describes robust and integrated approach used for design and development of lightweight bus structures for Indian city bus applications. An attempt is made to demonstrate the use of environment friendly material like aluminium in development of lightweight superstrutured city buses for India. Exercise involved design, development and prototype manufacturing of 12m Low Entry and 12m Semi Low Floor (SLF) bus models.

Urbanisation has led to an increased need for mobility in public transportation. Sensing the unfolding worrisome scenario, many countries have taken up different mass rapid transit solutions to alleviate the problem and restore the free flowing traffic. BRT should have been the logical choice particularly considering the lower capital costs involved and faster implementation. Comprehensibly the expectations of this class of vehicles will be high in term of quality and comfort to the passengers. Level of vibration and noise is an important indicator to evaluate vehicle's ride comfort. The challenges are to design the high powered Powertrain and Air Conditioning system nonetheless low interior noise, vibration and harshness correspondents to personal cars. This paper is an invention of, development work done in interior noise refinement of a bus. A prototype bus manufactured to meet all the requirement of BRT - premium segment urban bus.