I am finishing up my first playthrough of half-life and dang surface tension is a long hard level. Incredibly long actually, but a ton of fun. Are later levels longer/harder?
'On A Rail' and 'Surface Tension' have the highest amount of maps in the game, so no, there's nothing really that beats Surface tension for sheer scale. Most of the following chapters are 1-4 maps long, I think? However, The Lambda labs levels are quite non-linear and as people say, probably a bit tougher than Surface Tension (which has plenty of powerful tanks and stuff that you learn can be quickly and easily confused).