However, changes in rock type which ranged from soft earth to Millstone Grit caused engineering problems.

The tunnel sites also flooded regularly until Watt steam engines were introduced to operate pumps.

While the narrowboats went via the tunnel, boat horses were led over Harecastle Hill via "Boathorse Road".

A lodgekeeper (now Bourne Cottage at 53°4′57.26″N 2°14′35.75″W / 53.0825722°N 2.2432639°W / 53.0825722; -2.2432639) monitored the movement of the tow-horses, who were often led by boat children, as they crossed the high ground between Kidsgrove and Tunstall.

The Industrial Revolution had resulted in rapid growth and increased demand for coal and other raw materials in the Potteries.

Due to the amount of traffic and the slow process of legging, Brindley's Harecastle Tunnel had become a major bottleneck on the Trent and Mersey Canal by the start of the 19th century.

[6] Due to advances in civil engineering, the larger tunnel was completed after only three years of work, and at a cost of £113,000 (equivalent to £12.4 million in 2023).

The principal works were completed on 24 November 1826 when James Caldwell, chairman of the company, laid the last brick.

[7] As it had a towpath, horses could now pull boats through the 2,926 yd (2,676 m) tunnel greatly shortening journey times.

The towpath was built on a series of arches which allowed for circulation of water as boats were hauled through the tunnel.

As the tunnels led directly to the underground workings of the collieries, coal could be loaded straight into boats avoiding the need for it to be hauled to the surface.

Campbell gas engines, two 45 Kw direct current “Witton” dynamos and switchboard equipment.

The tug operated until 1954 when system of 3×38 inches (97 cm) fans was constructed at the south portal to improve ventilation for diesel-powered craft.