The Cumberland Gap Tunnel is a tunnel that carries U.S. Highway 25E under Cumberland Gap National Historical Park near the intersection of Kentucky, Tennessee, and Virginia. The east portal of the tunnel is in Tennessee and the west portal is in Kentucky; according to United States Geological Survey maps of the area, the tunnel does not enter Virginia. It is one of only two mountain vehicular tunnels in the United States that crosses a state line, the other being the East River Mountain Tunnel on Interstate 77 between Virginia and West Virginia.
The tunnel replaced a 2.3-mile (3.7 km) stretch of U.S. 25E between Middlesboro, Kentucky and Cumberland Gap, Tennessee that became known as "Massacre Mountain" due to the large number of travelers killed on the twisting mountain road over the Cumberland Gap pass.
Construction was administered by the Eastern Federal Lands Highway Division of the Federal Highway Administration for the National Park Service, with funding provided by both agencies as well as the states of Kentucky and Tennessee. While the project was in the planning phases, Kentucky and Tennessee both began widening their portions of US 25E leading to Cumberland Gap to four lanes.
The first step in construction was the boring of a pilot tunnel underneath the mountain, which revealed some unexpected construction challenges. The boring revealed underground springs and streams that would result in leakage of 450 gallons (1,700 L) per minute of water into the tunnel, regardless of outside weather conditions. To eliminate leakage into the tunnel, the tubes were lined with a thick PVC layer.
Construction of the actual tubes began on June 21, 1991. Excavation continued simultaneously from both sides, and the tunnels were joined on July 9, 1992. The tunnels opened to traffic on October 20, 1996.
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