ABSTRACT The classical shotcrete design approaches often ignore the effect of suction, which enables higher strength and, accordingly, a cost-effective temporary support. This paper addresses a numerical approach to design an economic tunnel temporary support considering suction effect on the mechanical characteristics of a simulated soil and shotcrete. Various suction profiles at: fully saturated, high degrees of saturation, transition zone and residual saturated zone, at various shotcrete thicknesses (t), strength (cc) and cohesion values were analysed. Nonlinear stability–suction relationships were obtained. The role of suction on (t) for the simulated soil was more significant in the transition zone and then in the zone of high degrees of saturation. Reduction in (t) increased with suction increase until beyond the residual saturation. An increase of suction from 58.86 to 78.48 kPa (in the transition zone) at cc = 400 kPa was sufficient to cause a reduction of 61.4% in (t).