The advanced 3D finite element limit analysis is employed to examine three-dimensional (3D) face stability of circular tunnels in undrained clays with the impact of strength non-homogeneity and anisotropy. The soil behaviour for all analyses is governed by the anisotropic undrained shear (AUS) strength model, which requires three anisotropic undrained shear strengths that are simply evaluated from conventional laboratory tests. The upper and lower bound solutions of 3D face stability of circular tunnels are accurately analyzed by considering four dimensionless parameters, including the cover-to-depth ratio, the overburden stress factor, the strength gradient ratio, and the anisotropic strength ratio. The significance of four dimensionless parameters on the stability load factor of the 3D face stability of circular tunnels, and the predicted failure mechanisms due to the influence of cover depth ratios, are also illustrated. A nonlinear regression analysis is employed to the computed data, which enables a new design equation of the factor of safety incorporating the conventional stability number. Thus, the new tunnel stability factors are proposed for the first time in the literature. A comprehensive application of the proposed safety factor equation is also presented and compared. The 3D effects of the tunnel face configuration between 3D geometry and 2D plane strain heading on the tunnel stability factors are also discussed. The new proposed design equation of the factor of safety provides an accurate and practical tool in assessing face stability of circular tunnels in non-homogeneous and anisotropic clays.
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