Booth Industries will manufacture and install 300 specialist tunnel doors designed to support the safe operation of the HS2 railway.
Production of safety-critical tunnel doors for HS2 has reached a major milestone after the first cross-passage door was completed at a purpose-built manufacturing facility in Bolton.
The project will see Booth Industries manufacture 300 cross-passage doors for the high-speed railway, supporting more than 130 jobs across the north-west while contributing to one of the UK’s largest infrastructure programmes.
The specialist facility, which opened in 2021, was developed to increase production capacity and introduce greater levels of automation. Located alongside the company’s main Bolton manufacturing site, the 600-square-metre factory has been designed to support volume production of highly engineered safety systems.
HS2 tunnel doors designed for extreme conditions
The cross-passage doors will form a vital part of HS2’s tunnel infrastructure. Installed between northbound and southbound tunnel bores, they will provide emergency access routes and help ensure the safe operation of the railway.
Engineered to withstand the demanding conditions created by high-speed trains, the doors must cope with significant pressure fluctuations as trains pass through tunnels. They are also designed to withstand extreme temperatures in the unlikely event of a fire.
Each door weighs approximately 600kg and incorporates a carefully balanced counterweight system that allows it to be opened and closed quickly during emergency situations.
Before entering production, the design underwent extensive fire resistance and fatigue testing to verify performance under operational conditions. Lessons learned from previous tunnel projects were incorporated into the design process to create a more standardised solution that supports efficient manufacturing, installation and maintenance.
Qasir Raza described the completion of the first production door as an important milestone as the project continues its transition from large-scale civil engineering works towards the installation of railway systems and operational infrastructure.
HS2 includes five deep twin-bore tunnels between London and the West Midlands, covering more than 27 miles. The longest is the 10-mile Chiltern Tunnel. The railway also includes five cut-and-cover tunnels extending for more than five additional miles.
Emergency walkways will run alongside the tunnels, with cross-passages linking both tunnel bores through specialist safety doors positioned at either end.
A successful trial installation has already taken place within the Chiltern Tunnel, providing valuable experience ahead of wider deployment across the network.
Booth Industries will also manufacture additional safety doors for Old Oak Common station and other tunnel-related assets along the route.
Mike Jenkinson said the contract builds upon the company’s 150-year engineering heritage while supporting investment in skills, manufacturing capacity and future growth opportunities within the region.
The wider HS2 project continues to progress across the route between London and Birmingham as installation of critical railway systems accelerates.
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