The first aluminium panels installed in the tunnel bulged
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Residents in a town have criticised the Highways Agency over tunnel repairs because they say bulges supposed to have been fixed are still visible.
Last year, aluminium panels were installed to hide unsightly walls in the Saltash Tunnel, one of the main road links into Cornwall from Devon.
Some bulged and were refitted. But locals say new panels are also bulging.
The agency said the latest bulges were a visual effect caused by light reflecting off surfaces.
There has been no extra cost to the taxpayer, but the additional panel work has contributed to delays in the completion of the £7.5m project to refurbish the tunnel by a year.
It may not be finished until spring next year.
However, the Mayor of Saltash, Baz Gregory, said: "I would agree that they are not as bad as they were, but they are still there.
"It was a complete removal of the bulges that concerned us. I cannot figure out why they have not cured the problem completely. It is not good enough to do half a cure."
The Highways Agency said the panels had been re-fitted to its satisfaction and to the original specification given to the contractor.
"The image of bulging is an entirely visual effect that changes with the time of day and the amount of sunlight reflecting off the panels.
The agency also said that there was no danger to the public.
Local businessman Paul Quick said: "All this time has been taken and we've ended up with bulging panels and an unsatisfactory tunnel.
"We have a low speed limit in the tunnel, so drivers can slow down and admire all the panels that are all distorted."
The Highways Agency said night-time closures and diversions at the tunnel should finish within the next few weeks.