In the fractured weak fault zone, rock mass exhibits low strength and poor self-stability. The geological conditions are complex, and when tunnels cross through fractured zones, significant deformations and collapses are prone to occur, leading to geological hazards. This paper investigates the in situ stress and deformation patterns of the Dongmachang Tunnel No. 1, proposing support solutions for addressing tunnel deformations through field experiments and numerical simulations. The on-site monitoring results indicate that despite implementing measures such as grouting reinforcement and temporary steel supports to control surrounding rock deformation, significant structural damage still occurred in the tunnel support system. The manifestations included severe sinking and cracking of the arch crown, strong inward deformation of the sidewalls, widespread cracking, crushing, and spalling of shotcrete, slight arching uplift, and severe distortion and twisting of steel arches forming a “Z” or “S” shape. To ensure tunnel safety and control the stability of excavations in weak fault zones, a comparison of tunnel deformation support schemes is conducted through field experiments and numerical simulations, indicating that replacing the upper tunnel structure and invert can effectively prevent tunnel deformations. These measures are vital for the sustainable development of tunnel.
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