Booth Industries has completed the first of 300 safety‑critical tunnel cross‑passage doors for HS2, marking a major milestone for both the project and UK manufacturing in the North West.
The first door has rolled off the production line at Booth’s purpose‑built 600m² manufacturing facility in Bolton, which opened in 2021 alongside the company’s main factory. The investment has expanded production capacity, enabled greater automation, and supports more than 130 skilled jobs in the region.
Designed for use in HS2’s deep twin‑bore tunnels, the cross‑passage doors play a vital role in the safe and reliable operation of the railway. They separate northbound and southbound running tunnels while providing emergency access between them if required.
Engineered for extreme tunnel conditions
Each door is engineered to withstand the intense pressure fluctuations caused by high‑speed trains, as well as extreme heat in the unlikely event of a tunnel fire. Weighing around 600kg, the doors incorporate a finely balanced counterweight system, allowing them to be opened and closed safely during an emergency.
To meet HS2’s stringent safety requirements, the doors have undergone extensive fire, pressure and fatigue testing, validating their performance in some of the most demanding operating conditions on the railway.
Importantly, Booth has drawn on lessons learned from previous tunnel projects, embedding best practice into a more standardised door and sub‑system design. This approach supports greater efficiency during manufacturing, installation and commissioning, while also improving consistency across the HS2 network.
Over the coming years, Booth Industries will manufacture and install all 300 doors, reinforcing UK‑based manufacturing and the North West rail supply chain.
Qasir Raza, Head of Delivery Tunnels and Lineside M&E at HS2 Ltd said:
“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.”
Supporting safety across HS2’s tunnel network
HS2 includes five deep, twin‑bore tunnels between London and the West Midlands, covering more than 27 miles in total. The longest of these is the 10‑mile Chiltern Tunnel. A further five cut‑and‑cover tunnels extend for just over five miles.
Each deep tunnel will feature emergency walkways and cross‑passages linking the two bores, with sliding doors at either end. Shallower cut‑and‑cover tunnels will also include emergency walkways, with a single door connecting the tunnels.
Following a successful trial installation in the Chiltern Tunnel, lessons learned are now being applied across the wider HS2 programme to improve efficiency and delivery.
In addition to tunnel cross‑passage doors, Booth Industries will also manufacture safety doors for HS2’s Old Oak Common station in West London, along with doors for other main works civil tunnel assets across the route.
Mike Jenkinson, managing director of Booth Industries, said:
“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.”
Progress continues as HS2 enters next phase
Once complete, HS2 will transform rail travel between London and Birmingham, while freeing up capacity on the existing West Coast Main Line for freight and local passenger services.
While progress continues across the programme, significant work remains along the 140‑mile route. HS2 Ltd Chief Executive Mark Wild is currently leading a comprehensive project reset, focused on delivering the remaining works as efficiently as possible and at the lowest reasonable cost.
Video and Image credits: HS2
