Tunnel Lighting Q&A with Kenall’s Michael Brereton

Lighting represents a significant yet sometimes overlooked portion of a tunneling project. Constructing large tunnels and caverns is fraught with challenges from dealing with difficult ground to logistical issues related to construction in major urban areas, but when the underground construction work is done and the reclaimed space is converted to civic purposes, proper lighting is paramount to safe and efficient day-to-day operation of the facility. 

To get a deep dive on the tunnel lighting market, TBM spoke with Michael Brereton, Transportation Lighting Sales Manager for Kenall. Based in Kenosha, Wisconsin, Kenall is one of the leading suppliers of lighting systems for the underground market, including transit and roadway tunnels. 

TBM: Can you start off by telling us about your background and experience in the market?

Brereton: It’s been a long journey. I have worked in sales and marketing for about 40 years, involved in the lighting and controls industry since 2007, and in my current position with Kenall since 2022. 

I started in the lighting market working on transit projects, mostly in the New York area. I have worked for a few different companies in the sector, which has given me broad experience, including working on road tunnels and with systems controls. Along the way I have held a variety of positions, including sales, product development and managerial roles.

How has the market evolved in tunnel lighting?

As a supplier, we work with owners, contractors and engineers to come up with the best solution to meets their needs. All of our work pivots around the Illuminating Engineering Society (IES) of North America’s Required Practice (RP 8/22). The IES requirements provide us with the paraments we use for our calculations to build the tunnel lighting design, ensuring that the light flows properly within each zone. Working within those guidelines, our clients know that they are getting a strong, viable design. 

Over the years we have seen the transition from fluorescent lights to LEDs, and now we are seeing more of a focus on optical design – specifically how the light flows through the transition zones and how much light is on the ground at any point throughout the tunnel. By using a better optical design, you potentially reduce the number of lights needed within a tunnel.

Of course, one thing that hasn’t changed is the harsh conditions within the tunnel environment and the impact they have on lighting equipment. Humidity, heat, salt and exhaust can have a corrosive effect on the fixture housing. At Kenall, we use 316 stainless steel for our fixtures because of its corrosion resistance capabilities. Stainless steel, in conjunction with a molybdenum compound, achieves a very high 5,000-hour salt spray performance, which mitigates blister and creep.

And of course we are seeing increased integration of control systems. Recently, we began working with a company called REIOS, which provides mesh network controls. Historically, mesh networks were tricky to use in tunneling applications because of the difficult geometries, heavy concrete, and other obstacles. REIOS has a history of using mesh networks in the mining industry, and we’re currently working with them on a project in the Fort Mifflin Tunnel at Philadelphia International Airport. 

How is the industry changing with respect to regulations or design preferences?

Another challenge that we see as a tunnel lighting manufacturer involves the Build America, Buy America – or BABA – regulations. On projects that are funded through the Infrastructure Investment and Jobs Act, we need to ensure that we are complying with BABA regulations. In our case, that means the steel and aluminum used in our fixtures are domestically sourced.

Being based in Kenosha, Wisconsin, we are well positioned to meet BABA requirements. But even though BABA was meant to make U.S. manufacturers stronger, it is still a very competitive market. Additionally, the requirements are scheduled to increase in the coming years, so it is a moving target. That can make it challenging to price jobs, especially on tunnel projects, which often have a lengthy development phase. 

How does an owner know that they are getting the best lighting options for their jobs?

Typically, we ask clients for contract documents, which disclose exactly what we need to build in terms of a fixture. We’ll look at the drawings to qualify and quantify heights for the mounting details. We also look at the governed speed of the roadway because it is key to determining a safe stopping distance.

In tunnels, it is important that we match the luminance of the external area with the threshold of the tunnel, because we don’t want to impede the ability of the driver’s vision to adapt once inside the tunnel. In other words, we need to allow time for the driver’s eyes to react as they enter and leave the tunnel. Another consideration is glare off  pavement and walls, so we need to consider the distribution of the lighting. 

In tunnel environments, lighting is essentially a science, and we use the RP guidelines to make sure the finished product isa safe zone for drivers.

Are the any common mistakes or misconceptions that you see? 

One issue that we sometimes see is wall packs are occasionally used in tunnel applications. These units are acceptable for pedestrian walkways or short underpasses, but for tunnels you need to be using roadway calculations that factor in mounted height of the fixtures and governed speed, as previously discussed, as well as the number and width of lanes, and the length of the tunnel. Once we have determined these, we can prescribe exactly what is needed. 

You also need to consider how the lighting is protected. Tunnels are highly corrosive environments, so the materials used to clad the light fixture are extremely important. 

It comes down to a Q&A with our client to ensure our lighting solutions are meeting their needs. 

At what point in the planning process should a client be thinking about lighting design? 

Typically, when a project advances to the construction phase, the lighting installations is one of the final steps in that phase. But if we are involved earlier in the process, we are better able to negotiate pricing and avoid escalation due to the impact of raw material cost increases or tariffs. 

It is also important to remember that all these projects have their own challenges and unique needs. Typically, it’s not a matter of picking out a standard fixture from the website In most instances, the mounting height and the tilt need to be custom designed based on the unique needs of the project. 

As much as we strive for a perfect world, it doesn’t always end that way. At times, we have to pivot as we move through the process. 

For example, we recently completed a job on the Hubbard’s Cave project in Chicago. That project involved the refurbishment of a tunnel lighting system, which coincidentally was also done by Kenall, that originally went into service in 1962. Due to the configuration of the I-beam supports, we needed to design a custom mount that would allow our fixtures to be installed. We also increased the lumen levels from 16,000 to 25,000 to meet the project specifications. 

What is your view on the future of the tunneling market? Do you see it continuing to grow?

There is a big demand for infrastructure construction and repair, and we are seeing substantial investment into the market as a result of the infrastructure bill. At Kenall, we have experienced a lot of construction activity across our markets, which we expect will continue in the foreseeable future.