Weekly Status Report
4/13/2011
TUNNEL LIGHTING
Immediate Action
Following the February 8 incident, MassDOT electricians performed hands-on inspections of
the 25,000 tunnel light fixtures. The inspections included pry tests on the 250,000 light
fixture clips. A total of 4,270 clips, or 1.7%, had failed or were failing due to corrosion
issues. The failed clips were moved and secured as necessary.
This action is complete.
Inspections
Preliminary safety inspections and lighting fixture clip repositioning work were performed
by MassDOT electricians and completed on Saturday March 26. We are continuing annual
tunnel inspections as required per previous policy directives. These annual tunnel
inspections include inspection of all overhead elements including the lighting and take
several months to complete. Due to the light fixture issue, the operating procedures for the
inspections have been enhanced to include a more detailed, hands-on inspection of the
components of the light fixture itself as well as the overall condition ranking of the fixture
and connection to the ceiling. These inspections are being conducted by four consultants
(AECOM, HNTB, Transystems and Dewberry). Normal protocol during the inspection
process requires that when critical or "immediate action" items are identified, they are
immediately reviewed and forwarded to the appropriate MassDOT personnel (electricians,
plumbers, millwrights, etc) for action or repair. Corrective measures taken to date specific to
the lighting issues are being tracked.
Tunnel areas worked in the past week include portions of I-90 EB and WB, Ramp B (South
Boston to I-90 WB and Ramp D (I-90 WB to I-93).
Federal Highway Administration (FHWA)
Weekly meetings with FHWA have begun and are scheduled every Tuesday. To date,
MassDOT District 6 staff has met twice with FHWA and are working cooperatively on the
stepped approach to lighting repair.
MassDOT is in discussion with FHWA about the potential use of Central Artery/Tunnel
(CA/T) Trust Funds for the purpose of providing access to funds to address immediate and
interim inspections and repairs. CRC 17, a request for use of CA/T Trust Fund, includes two
scope elements: (A) I-90 Lighting (the replacement of lights that had been removed when the
ceiling accident occurred; and (B) Lighting Support Clips, to investigate and repair the
corroded wire way lips. The estimated cost is $1.2 million, which would cover some
investigation work and temporary repairs only.
Preliminary Analysis of Light Fixture Corrosion
A preliminary analysis of the failed light fixture wire way and base has been completed by
Massachusetts Materials Research, Inc (MMR). The initial analysis indicates that the fixture
failure was due to severe corrosion of the aluminum wire way at the locations where the light
assembly was attached with stainless steel clips. The cause of the corrosion was the chloride
(salt) environment which was likely the result of roadway snow and ice treatment and
removal efforts.
Further, in the process of attaching the light body to the wire way, the stainless clips may
have breached the protective coating covering the aluminum wire way which when coupled
with the salt environment would initiate and ultimately accelerate the corrosion.
MassDOT engineers are reviewing the preliminary findings which will be used to determine
next steps. FHWA has been given copies of the MMR Report.
Interim Repair (Redundant Support)
An on-call consultant (Transystems) has been charged with engineering the redundant
support system. This repair is intended to be reliable for a minimum of five years. Selection
and engineering of the system is expected to be complete by the middle of May. MassDOT
will use an expedited/emergency process to procure the materials needed as well as the
installation contractor. Installation will begin as soon as the system is chosen and material
procured.
Long Term Repair
MassDOT will begin the process of selecting a consultant to evaluate light fixture
repair/replacement. Personnel are also reviewing inspection data, performing fields surveys
to help develop the scope and quantity of where fixture retrofit and/or replacement is
warranted. On April 3, 2011 MassDOT began washing all lighting fixtures and continues to
perform field reviews of the extent and severity of the coating failure and corrosion
throughout the tunnel system.
Legal has advised that the standard conflict of interest provisions of MassDOT’s contracts
will prohibit any of the consultants involved in the original design from participating in either
the Interim or the Long Term Repair process.
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Cost Recovery
Both manufacturers (NuArt Lighting and Schreder Lighting), and all contractors (Modern
Continental, City Lights Electrical, Mass. Electric Construction Company, and Fischbach and
Moore Electrical Group) that installed the fixtures have been put on notice. Also, notice has
been sent to the following design firms: Sverdrup Engineering a/k/a Jacobs, Bechtel/Parsons
Brinckerhoff, and FST/HNTB.
As analysis continues on the root cause of the tunnel light fixture corrosion issue, MassDOT
will continue to aggressively pursue remedial cost recovery action against design,
construction, manufacture and installation contractors.
Independent experts will be brought on board to determine if the design, manufacture,
installation, and/or products received were appropriate for the tunnel systems.
Massport
Attached is the report submitted by Massport on April 6, 2011 on the status of light fixtures
in the three tunnel sections under its control.
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Fixtures
Bolt Conditions
Bolted
Connections
PP
LC
MC
Loose
UT/NLN
Misaligned
Missing
TAD
450
2700
960
957
0
5
1217
7
2
Arrivals
439
2634
2115
2108
10
61
0
23
45
1A-Arrivals
111
666
512
512
0
1
0
3
0
1000
6000
3587
3577
10
67
1217
33
47
Fixtures
Fixture/Lens
clips
PP
LC
MC
Fixture Clip Conditions
Lens Clip Conditions
Losses 100% Loss Broken/Loose
PP
LC
MC
Loose
Broken
Missing
TAD
450
4500
268
212
56
0
0
7
0
0
0
3
1
0
Arrivals
439
4390
4349
4197
142
62
19
19
2392
2392
0
5
10
3
1A-Arrivals
111
1110
1043
1043
0
2
0
7
353
353
0
2
2
0
1000
10000
5660
5452
198
64
19
33
2745
2745
0
10
13
3
PP
Peeling Paint
LC
Light Corrosion
MC
Moderate Corrosion
UT/NLN Underthreaded and/or Non-Lock Nut