Canadian National Railway Co. v. Royal and Sun Alliance Insurance Co. of Canada is an important decision from the Supreme Court of Canada which grapples with defining the scope of the “faulty or improper design” exclusion within the context of an “all risks” insurance policy. An “all risks” policy was obtained by CNR from the respondent insurers in respect of the construction of a railway tunnel. A tunnel boring machine (TBM) was halted when dirt penetrated its cutting head and threatened the integrity of the main bearing that drove the machine forward. The project was consequently delayed by 229 days and its costs thereby greatly increased. CNR had negotiated a builders’ risk policy with the insurers that insured them against “ALL RISKS of direct physical loss or damage … to … [a]ll real and personal property of every kind and quality including but not limited to the [TBM]” but excluding both “the cost of making good … faulty or improper design” and “inherent vice”. The design engineers anticipated that the TBM would have to withstand 6,000 metric tonnes of pressure from the weight of the soil and water above as it progressed under the river. The TBM was designed to accommodate those pressures. The trial judge found that despite its failure, the innovative design did “accommodate”, within the then limits of the state of engineering knowledge, all foreseeable risks encountered in the digging conditions in the tunnel. He acknowledged that the design proved in the result to be defective, but found that it was not “improper” or “faulty” according to the state of the art at the time the design was finalized. He concluded that the design not only addressed all reasonably foreseeable risks but all foreseeable risks however unlikely or remote. He therefore held the insurers liable to the CNR for $29,582,638.91 including pre-judgment interest, plus $1,150,837.35 in costs.
The Ontario Court of Appeal, by majority, allowed the appeal. In its view, a design error may, but need not, depend upon designer negligence. A design must “‘take into account’, ‘accommodate’, ‘provide for’ and ‘withstand’ all foreseeable risks” however unlikely or remote. If, in these circumstances, there was a failure attributable to “design”, the exclusion applies. In a 4:3 decision, a majority of the Supreme Court allowed the appeal and held that the Court of Appeal’s conclusion read the qualifying words “faulty or improper” out of the exclusion, and hence greatly expanded its scope. In the majority’s view, the “all risks” policy afforded the CNR greater protection than that which the majority in the Court of Appeal was prepared to allow. At the time of contracting, all parties realized that this was to be the largest earth-balance TBM ever built. Leading experts were enlisted to provide what was described as a “state-of-the-art machine”. The “all risk” policy was written to cover physical damage to an innovative piece of equipment almost the length of a football field operating on a scale with which the state of the art had no previous experience. The policy did not exclude all loss attributable to “the design”, but only loss attributable to a “faulty or improper design”. The design exhausted the state of the art but left a residual risk. Failure is not the same thing as fault or impropriety. In the majority’s view, the insurers did not meet the onus of bringing the loss within the exclusion. A design is not “faulty or improper” simply because it falls short of perfection in relation to all foreseeable risk. The majority of the Supreme Court distinguished a decision by the High Court of Austrailia (Queensland Government Railways v. Manufacturers’ Mutual Insurance, Ltd.) which holds that that the fact of failure not only speaks for itself but, once it is attributed to the design, it discharges the insurers’ onus of proof. The majority did not agree that a design can be said to be “faulty” if it conforms to the state of the art, as was found by the trial judge.
The minority, however, stated that the term “faulty or improper design” does not imply the introduction of a “state of the art” standard against which an impugned design is to be compared. As explained in Queensland, the distinction that is relevant is between a design that is defective and design that is free from defect. The question is whether or not the damage to the insured property was due to an inability of the design to fulfil its purpose in the foreseeable conditions of the property’s use. It was not appropriate to create a test akin to negligence when nothing in the term “faulty or improper design” in the insurance contract implied the introduction of the law of torts. The term “faulty or improper design” attaches to the thing that was designed, not to the work of the design engineers. Whatever standard their work meets or does not meet, the thing designed either works for its intended purpose or it does not.
The Supreme Court’s decision is important for insurers as it poses the risk of transforming an “all risks” policy into a warranty. An insurer will be left covering a loss arising from the limitations of science. This may not exactly be the kind of risk the insurer signed up for. However, the case turns on a singular set of circumstances involving a highly complex and cutting edge piece of machinery. The case does not allow the insured to escape the exclusion simply because the machine was not negligently designed. Although not a standard of perfection, the majority’s “state of art” standard is still quite formidable.
Raj K. Datt