The first of 300 safety-critical tunnel cross-passage doors for HS2 has rolled off the production line at Booth Industries’ specialist manufacturing facility in Bolton, marking another milestone as the project moves from major civil engineering works towards railway systems installation.
Manufactured at a purpose-built 600m² factory opened in 2021, the doors will form a vital part of HS2’s tunnel safety infrastructure, providing emergency access between northbound and southbound tunnel bores while withstanding the extreme operational conditions created by high-speed rail operations.
The facility, located alongside Booth Industries’ historic Bolton manufacturing site, has expanded production capacity and introduced greater automation, supporting more than 130 jobs and strengthening specialist engineering capability in the North West.
The completion of the first door highlights the growing role of UK manufacturers in delivering the systems and equipment that will ultimately enable the railway to operate safely and reliably.
Each cross-passage door has been engineered to withstand substantial pressure fluctuations generated by trains travelling at high speed through the tunnels, while also providing fire protection in emergency situations.
Weighing approximately 600kg, the doors incorporate a carefully balanced counterweight mechanism that allows them to be opened and closed quickly and safely if passengers need to evacuate from one tunnel bore to the other.
The design has undergone extensive fire, fatigue and performance testing to meet HS2’s stringent safety requirements. Lessons learned from similar tunnel systems elsewhere have also been incorporated into the final design, supporting a more standardised approach across the railway and improving efficiency during manufacturing, installation and commissioning.
Qasir Raza, Head of Delivery Tunnels and Lineside M&E at HS2 Ltd, described the completion of the first door as an important step in the evolution of the project.
“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,” he said.
“The cross-passage doors 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.”
The contract covers the manufacture and installation of doors across HS2’s extensive tunnel network, which includes five deep twin-bore tunnels stretching for more than 27 miles between London and the West Midlands. The longest of these is the 10-mile Chiltern Tunnel.
Each deep tunnel includes emergency walkways running alongside the railway, with cross-passages linking the two tunnel bores at regular intervals. In the event of an incident, passengers would be able to move safely between tunnels through these protected routes.
Booth Industries has already completed a successful trial installation within the Chiltern Tunnel, with lessons from that exercise now being applied across the wider programme.
In addition to the tunnel doors, the company will also manufacture safety-critical doors for HS2’s Old Oak Common station and other tunnel-related infrastructure across the route.
The contract represents a significant boost for UK manufacturing and continues Booth Industries’ long-standing involvement in major infrastructure projects.
Founded more than 150 years ago, the company has supplied specialist engineering products to sectors including rail, defence, energy and infrastructure, building a reputation for delivering high-performance safety systems in demanding environments.
Managing Director Mike Jenkinson said the HS2 programme was helping to strengthen manufacturing skills and capacity in the region.
“Booth has over 150 years’ manufacturing heritage in Bolton, delivering performance-critical components for some of the world’s most demanding industries,” he said.
“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.”
For the wider rail supply chain, the milestone demonstrates how the focus of HS2 is increasingly shifting from large-scale earthworks, structures and tunnelling towards the installation of the complex systems required to operate the railway.
While significant construction activity remains across the 140-mile route between London and Birmingham, the production of operational railway assets such as signalling equipment, electrical systems, control facilities and safety infrastructure represents the next major phase of delivery.
As HS2 progresses towards testing and commissioning, manufacturers across the UK are expected to play an increasingly important role in delivering the technology and systems that will underpin the railway’s long-term operation.
