Key Statistics:
Contract Value:
£40 Million+
Project Duration:
2016 - 2026
Scope:
Manual and Power Operated Security & Blast Doors
Project Overview
- Booth Industries was contracted to design, manufacture, test, install and commission specialist security and blast doors for a new secure nuclear facility.
- The doors were designed to the most exacting nuclear and seismic safety standards, ensuring critical protection in one of the world’s most sensitive environments.
- Building on our proven expertise in nuclear applications, we provided a full turnkey package covering mechanical, electrical, control and instrumentation design.
What were the project complexities?
- Highly classified design requirements — all work carried out in secure on-site facilities.
- Design scope included: Mechanical engineering. EC&I (Electrical Control & Instrumentation). Local PLC software design and integration.
- Strict quality assurance with multiple hold points during fabrication.
- Logistical challenges: Doors weighing up to 10 tonnes. Complex installation across confined corridors. Custom trolley hangers developed to manoeuvre doors without cranes.
- Functional requirements included strict tolerances for parallelism, perpendicularity, flatness, and controlled forces during operation.
What did we overcome?
- Built a full trial assembly including drive systems and software to de-risk the programme.
- Manufactured full-scale units for FAT testing to satisfy nuclear safety case requirements.
- Developed temporary jigs and bracing systems to maintain tolerances during curing and installation.
- Ensured doors could be operated by a person of 50th percentile strength while also offering mechanical drive operation.
- Successfully demonstrated all requirements during client-witnessed FAT testing at our Bolton facility.
- Rapidly adapted to significant design changes during the project through our team of over 30 mechanical and electrical design engineers.
Magnetic particle testing. It is a non destructive testing (NDT) process. The principle of the method is that the specimen is magnetised to produce magnetic lines of force, or flux, in the material.
What did Booth achieve?
- Delivered a world-first solution for nuclear blast and security doors.
- Achieved full material traceability across thousands of parts.
- Over 30,000 fabrication hours delivered thanks to the skill of our welders and fabricators.
- Consistently met the highest quality and safety standards, protecting one of the UK’s most critical national assets.
