Grouting reinforcement plays an important role in repairing fractures and improving the strength of the surrounding rock. To address practical engineering challenges such as caving and chip off-falling of surrounding rock in deep roadways, normal splitting was adopted to prefabricate fractures on rock samples gathered from underground coal mines. This was done to better match the rock fracture specimen with actual conditions. Based on the elementary unit of a fracture surface, systematic experiments were conducted on the tensile properties of rock fractures after grouting reinforcement, and the shear properties were studied after considering the presence of gas. As per the results, the tensile strength of rock fractures increased with the increase in viscosity of grout, but the overall tensile strength was relatively low. The overall tensile effect of surrounding rock was improved less by grouting approach. When the presence of fracture gas in grouting was considered, the peak shear strength of fractures after grouting was 8.34–29.9% less than that without considering the fracture gas. The cemented pore surface produced by unsaturated cementation in the grouting reinforcement was the main cause of reduction in cohesion and frictional angle of rock fractures. The conclusions of this study have great significance for guiding engineering grouting and evaluating the grouting effect.

Mudstone material in a deep roadway is under the coupled stress-seepage condition. To investigate the permeability change and damage development during rock excavation in roadways, a stress-seepage damage coupling model has been proposed. In this model, damage capacity expansion of mudstone material is considered as the initiation and propagation of micro-cracks and the fracture penetration. A damage variable is introduced into the proposed model based on the principle of minimum energy consumption. As a result, an elastoplastic damage constitutive equation is established. Then, the permeability evolution equation describing the micro-macro hydraulic behavior of mudstone is deduced via percolation theory, which can describe the characteristics of sudden permeability change after rock capacity expansion. Furthermore, a finite element model is established based on commercial finite element software-ABAQUS. The numerical model was firstly verified by comparison between experimental and simulation results. On the basis of it, numerical investigation of the temporal and spatial evolution law of pore pressure, damage and permeability coefficient during roadway excavation is undertaken. The numerical results indicate that with increase of construction time, pore pressure first increases and then decreases, while the damage zone and permeability coefficient increase gradually and finally nearly keep constant. The proposed coupling model and finite element method can describe damage and permeability evolution for mudstone material under coupled stress-seepage well.

Shield tunneling in highly fractured karst water-rich conditions easily results in water inrush disaster or even causes the roof of the karst caves to collapse. Severe water inrush disasters have occurred during the EPB (earth pressure balance) shield machine of the Jinan Metro Line R1 advanced through a karst and fissure groundwater-rich limestone ground in the spring area. To cope with the extreme water inrush risk, a multi-step combined control technology was put forward. First, a detailed geological exploration was carried out by ahead geophysical prospecting using high-density resistivity method, geological radar, etc., and geological borehole drilling was conducted from the ground surface before excavation. As a result, the distribution orientation, size, fissure development degree, and water inflow channel within the surrounding rock of the karst caves were detected. Second, multi-step grouting was performed to reinforce the surrounding rock, including pre-grouting treatment and filling rock blocks to the big karst caves from the ground surface, multiple grouting with a small amount of inert slurry each time inside the tunnel, and secondary circumferential hoop grouting at the shield tail. Third, the tunneling process was optimized, including optimizing the tunneling parameters, making full use of the air-pressurized tunneling technology of the EPB to press bentonite into the fractures around the excavation cabin to seal the fissure water, and using the drainage system of EPB and muck improvement technology to reduce the water inrush disaster. Meanwhile, shield protection slurry technology is applied to cutter inspection and replacement in the pressurized chamber under dynamic water flow environment of the spring terrain. The practice shows that the water inrush on the tunnel face is obviously alleviated after the shield machine advanced into the grouting area. According to statistics, the water inflow on the tunnel face decreases from about 4 m³/h before treatment to less than 0.3 m³/h after the abovementioned control, and the water seepage between the segmental linings reduces to almost zero. The average advance rate increased from 3 m/day without stopping or even zero when the shield machine needs to shut down 2–3 days for drainage to about 6 m/day. In addition, the treatments prevented the shield machine from jamming and the head descending disaster. This study provided a reliable control method for shield tunneling through the karst and fissure water-rich area and played an essential role in protecting the spring water.