Josh Metcalf on the Long Tunnel

Some of the Authority’s biggest challenges couldn’t be solved with traditional construction methods. Josh Metcalf explains how the “Long Tunnel” became one of the most significant engineering achievements of the Surface Water Supply Project while minimizing impacts to surrounding communities.

There is one project that is very symbolic for the board, and I think for the Authority overall.

There was a very challenging section of the Surface Water Supply Project. Within that section is a specific project known as Segment B3, what we call the Long Tunnel.

It ended up being a tunnel more than four miles long through one of the most congested areas of Houston, including Interstate 45, the Hardy Toll Road, and the Union Pacific Railroad corridor.

This area didn’t have good alternatives. Normally, we install water lines using open-cut construction.

We presented various options to the board that would have had much greater community impacts. The board was very thoughtful in working with the engineering team and the program team to develop a tunneling solution.

The tunnel is more than 32 feet deep and 132 inches in diameter, so you’re able to walk through it. It’s quite large.

Typically, we advanced about 30 feet per day. The contractor operated around the clock, usually with two excavation shifts and a third overnight shift dedicated to repairs and maintenance on the tunnel boring machine.

It’s been a huge success. It limited impacts to residents and, at the time, I believe it was the longest large-diameter water line tunnel ever built in Houston.

We crossed every major freeway, and we’re very excited with the result, happy that it’s completed, and very proud of it.

Watch more from The People Behind the Progress Video Series:
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Published On: July 20th, 2026Categories: The People Behind the Progress Video Series

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