Booth Industries - Case Study

Project Name:    The Northern Line Extension

Contract Value:  circa £5 Million 

Project Start Date:    2019

Project Completion Date:  2021

Scope:      328 high performance steel doorsets

The Northern Line Extension project was conceived in order to extend to Battersea the existing London Underground Northern Line, which also included plans to construct two new stations.

Booth Industries were contracted to design, manufacture and install 328 steel hinged doors for London Underground/Ferrovial Laing O’Rourke as part of the scheme.

Our experience of having previously delivered similar large rail projects, as well as our ongoing involvement with the Crossrail project, meant that we were the obvious choice to provide all the high performance tunnel & station doors.

This demanding contract involved developing and certifying a variety of new door designs, with the added complication of delivering the programme without disruption during the evolving Covid-19 pandemic.

Drawing on our wealth of experience in the industry, our cross-departmental team of engineering, procurement, manufacturing and project management specialists applied learnings from previous projects to develop new designs, optimise manufacturing processes and co-ordinate installation of these crucial, performance-assured doors quickly and effectively.

We worked closely with our trusted team of treatment specialists and installation contractors to ensure the project was completed safely and on time, despite the circumstances surrounding Covid-19.

Our collaborative-approach and strong communication throughout were key to the programme’s success.

What were the project complexities?

The demands of the project were such, that a variety of multi-performance doors were required, and they all needed to be assured and certified.

Altogether, there were a total of 96 different door types & configurations that we were required to provide.  These ranged from simple fire doors, to acoustic doors, security doors, insulated doors, as well as doors with a combination of some or all of  these performance criteria. Additionally, there were pressure relief and blast doors, and all were supplied in either mild steel or stainless steel construction.

What did we overcome?

Of course, the Covid-19 pandemic had a big effect on everything once it started in early 2020. By which time, Booth were already underway with the project and committed to a programme to complete.

Our commitment was such that we were determined to create emergency contingency plans to manage the project through to completion.  Firstly, our engineers were relocated to home-working with full access to our servers and digital models so that the design process could continue as planned. Our manufacturing premises were modified so that production could continue with added safety measures in place.  Doors when completed were stock-piled & stored ready for when installation could continue on site, and when the site was re-opened we increased installation resource in order to recover any time lost on the programme.  Our site operations continued despite ongoing lockdowns, and the team worked strictly under all new safety restrictions.

What did Booth achieve?

Having to design , manufacture & install over 300 doors with 96 different types was a very challenging prospect, but one which we took on undaunted and with a promise to the client that we would deliver everything they asked for.

Each door type was designed and modelled, and we had to hold weekly design workshops with our team of 10 engineers in order to keep up with the ongoing requests for changes by the architects.

Booth managed to achieve the completion of the project through working closely with testing & certification bodies , predominantly Warrington Fire & UL, in order to physically test or assess all different bespoke variations that the client had requested.

We delivered and installed our last door on the Northern Line Extension in May 2021 .

Installation of doors on site:

Fire testing of doors for the project:

Contact Us

Booth Industries
PO Box 50
Nelson Street
Greater Manchester

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01204 366333
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From the South: Follow the M6 and M56 and M60 to A666 St Peters Way
From the North: Follow the M6, onto the M61, leave at exit 5 and follow the A676