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TKE team works with DIA-DEN to realize key, comprehensive escalator modernization in Denver, Colorado.

by Jeffrey A. Massey
photos courtesy of TKE

Since the vast majority of the conveyances — elevators, escalators and moving walks — at Denver International Airport (DIA-DEN) were installed in 1992 when the airport was built, the facility’s owners felt a pressing need to modernize them. TK Elevator (TKE) recently undertook and successfully completed the modernization of 16 key escalators on behalf of DIA-DEN and a key client, building on a relationship that has seen TKE teams replace/modernize a significant portion of the 350-plus conveyances at the airport over the past few years.

Currently, DIA-DEN is the third-busiest airport in the U.S. It is on target to reach 100 million passengers in the next few years. Because of this, the DIA-DEN management team committed an initial US$50 million to focus on the upgrades of elevators, escalators and moving walks. Jeff O’Neal, service operations manager — DIA-DEN, explained that “the conveyance equipment at the airport had lived well beyond its useful life, and the ongoing downtime for numerous units, coupled with the continual year-after-year passenger increase, were the impetus items for the airport to pursue conveyance upgrades.”

While such a modernization process is necessary for the effective operation of the airport into the future, the conveyance upgrades posed a significant set of challenges for airport management, passengers, authorities and other stakeholders — notably, contractor TKE.

A dedicated team from TKE worked with various entities and overcame multiple challenges to realize a major escalator modernization project in 2023, resulting in vastly improved reliability and safer, smoother and quieter operation for a total of 16 units serving the high-profile Concourse B at DIA-DEN. The team replaced Montgomery HR escalators installed in 1992 with the TKE ES-Power Tugela heavy-duty modernization product. Prior to modernization, the 30-year-old escalators experienced significant downtime, frustrating DIA-DEN passengers, airlines, concessions and other key stakeholders. When TKE took over equipment servicing more than six years ago from a competitor, more than 60 of the units were out of service. TKE systematically serviced, repaired and brought the units back into service, thus creating a trust with DIA-DEN that translated into assistance with the modernization process of the same conveyance units, including the above-noted 16 escalators.

The need to get the modernized escalators up and running in a timely manner was a significant driving force, and a tight installation timeframe was stipulated by all involved — in particular a key DIA-DEN client: United Airlines (UAL). UAL agreed to the process, timing and sequencing of the job, which ultimately helped facilitate communication between TKE, the airport and UAL. As a result, the overall modernization was completed well ahead of schedule and received no complaints from the parties/entities involved.

Some of the various project challenges included:

• Limited availability/use of craning and gantry units with the Concourse B center core next to the Automated Guideway Transit System (AGTS) train 
• The initial stipulation that older units be kept operational during modernization, resulting in increased passenger traffic on these critical escalator units
• Work and passenger traffic areas right next to each other and the need for safe separation of both areas
• Night shift work arrangement to minimize noise and material movement restrictions and provide a safer modernization process with less passenger/airport personnel interface

TKE began the ES-Power escalator modernization project well before installation commenced by engaging with the airport to ensure the proper products and options were specified and ordered and that the timing and overall process was acceptable for the airport and relevant stakeholders. The entire team was kept advised of the project throughout (including by weekly photo reports) and a large cache of spare parts was ordered for the on-site service team to ensure the escalator equipment continues to run with minimal downtime. Moreover, TKE engaged with the airport operations team, service team and code authorities to ensure all were involved in the modernization process and able to interface with one another for the ultimate benefit to the airport and the timing of the project, which was ultimately completed several months early and prior to the busy U.S. Thanksgiving holiday.

Tony Makela, operations and project manager for modernization for TKE at DIA-DEN, observed:

“As part of the current proactive partnership with the airport and through being the service provider for the entire airport, TKE understands its needs, and thus focused on modernizing the eight initial high-traffic escalators leading from the AGTS/train platform to the main concourse level in Concourse B, with the process occurring entirely at night to minimize noise and traffic concerns.”

Initially, TKE began with the south side, modernizing four escalator units at a time with TKE’s heavy duty ES-Power Tugela in-truss modernization solution supplied by TK Norte in Spain, then completed the second set of four escalator units on the same side — consecutively. Makela further said:

“We worked with the DIA-DEN airport team to identify and concentrate on the Concourse B escalators due to the vintage of the units, continually increasing passenger loads and the large number of flights coming into and leaving the concourse, which exclusively serves DIA-DEN’s largest airline, United Airlines.”

With TKE’s ES-Power Tugela in-truss modernization solution, the escalators were completely stripped down to the existing trusses, cleaned, painted and new upper/lower modules, tracks, balustrades, handrails, steps, skirts, outer decking, end plates, walk-on plates, wiring and associated accessories/equipment were installed on each escalator to build a new heavy-duty unit onsite.

Lee Blevins, area vice president for TKE Southwest, said:

“The unique TKE ES-Power Tugela in-truss escalator modernization/replacement solution helped keep passenger traffic around the units moving at a consistent pace while not having to close off large sections of public areas due to unnecessary craning, gantry and barricading requirements.”

With the new TKE ES-Power in-truss modernization product, the DIA-DEN received upgraded escalator equipment including the additional added features:

• Tugela heavy-duty escalator design (improved over original installation)
• Handrail-sanitizing devices
• Antimicrobial handrails
• LED skirt band lighting
• Comb segment lighting at each end
• Directional/traffic lights at each end (green/red)
• Sleep mode/radar operation
• TKE’s MAX predictive monitoring system
• Step sound deadening
• Ethernet port for additional communication capabilities

The new TKE ES-Power Tugela escalators offer heavier duty-rated equipment, quieter operation, enhanced visibility through the improved handrail/glass design, increased safety through additional features and safety items, improved energy efficiency and improved lighting over the initial escalators installed in the early 1990s.

Based on the success of the initial eight Concourse B escalators turned over to the airport for use following the modernization process, TKE and the airport then agreed to complete the next eight escalators on the north side using the same ES-Power in-truss modernization product. However, with this set of units, TKE completed all eight escalators at the same time to expedite the process.

Several factors were unique to the project, including:

• TKE worked with the airport over the last several years to budget/encumber and commit funds for the overall conveyance modernization project process due to the high-profile nature of the airport, antiquated vintage of the conveyance equipment and increasing passenger traffic.
• TKE’s active involvement in assisting the airport in selecting its conveyance units for modernization, including the above-noted 16 escalators, provides the DIA-DEN with an improved reputation in the community, with the traveling public, with stakeholders and with the area taxpayers, as the ongoing investments in critical conveyances are being made and seen by all.
• TKE worked with the airport to ensure that the passenger traffic was unimpeded throughout the modernization process.
• TKE worked with the airport to ensure that its largest client, UAL, which has exclusive use of Concourse B, was part of the decision and planning process.
• TKE’s unique modernization process and active involvement with product specifications created a streamlined modernization process in which multiple stakeholders were involved and signed off on the schedule, timing and methods used for the modernization of the 16 escalators and for future escalator units. In addition, TKE provided upgraded equipment with higher visibility and an increased safety factor based on the above noted features included with/added to the new ES-Power escalators.

With TKE’s ongoing successes on the various DIA-DEN modernization projects, including the recent modernization of the 16 Concourse B in-truss escalators, the DIA-DEN team has awarded TKE a third phase of conveyance modernization for further units to be modernized/replaced moving into 2024-26.

Additional Project Partners

DIA-DEN is owned by the City and County of Denver. Gilmore Construction as a subcontractor to TKE served as general contractor on the project, and Intermountain Electric was the electrical supplier.