Booth Industries has delivered the first of 300 safety-critical cross-passage doors for the HS2 rail project from its new Bolton manufacturing facility, safeguarding more than 130 jobs in the North-West.

Opened in 2021, the purpose-built 600 square metre factory sits beside the company’s existing Bolton headquarters and has increased production capacity through greater automation to support large-scale manufacturing.

Cross-passage doors are an important safety feature within HS2’s tunnel network, separating northbound and southbound bores while providing emergency access between tunnels when required. The doors are designed to cope with substantial pressure changes generated by passing high-speed trains, as well as extreme temperatures in the unlikely event of a fire.

Each door weighs around 600kg and is fitted with a counterweight system to ensure it can be opened and closed quickly during an emergency. The units have also undergone extensive fire and fatigue testing to verify performance in demanding tunnel environments.

Design improvements drawn from previous tunnel projects have been incorporated into the programme, helping create a more standardised approach to tunnel doors and associated systems across HS2. The move is expected to improve efficiency during manufacturing, installation and commissioning, while increasing consistency across the railway.

Booth Industries is now set to continue manufacturing and installing the remaining doors for the wider HS2 programme, alongside safety doors for Old Oak Common station and other tunnel assets on the route.

“It’s great to see the first cross-passage door come off the production line. This is a key milestone as we start to transition from civil engineering to installation of the critical systems needed to operate the railway.

“The cross-passage doors being a key component of the tunnels may not be visible to passengers, but they will play a crucial role enabling us to run a fast, reliable and safe service, day in, day out.”

Qasir Raza, Head of Delivery Tunnels and Lineside M&E at HS2 Ltd.

“Booth has over 150 years’ manufacturing heritage in Bolton, delivering performance-critical components for some of the world’s most demanding industries.

“We are proud to be supporting another nationally-significant infrastructure project in HS2. The cross-passage doors contract not only builds on our unique heritage and expertise, but also supports welcome investment in skills and capacity that will drive future growth and secure vital engineering skills in the area.”

“It’s a great feeling to see the first cross-passage doors roll off the production line, marking a significant landmark in the delivery of this contract.“

Mike Jenkinson, managing director of Booth Industries.