The theoretical model of twin curved shield tunnels and refined numerical model considering the characteristics of wedge-shaped segment ring joints were established in this paper. Two construction schemes of taking the inner side or outer side of the twin curved tunnels as the first tunnel were conducted for comparison. Then two main characteristics of curved tunnel construction (over-excavation and yaw excavation loadings) were taken as variables to explore their response to the approaching construction caused by unsynchronized driving of twin curved shield tunnels. The ground surface settlement troughs obtained by the analytical solution and numerical simulation are in good agreement with the monitoring result. On the condition that the curved tunnel at the inner side is taken as the first tunnel, the excavation will intensify the ground settlement and the internal forces of its segment. In the case that the overcutting gap is not of large volume, it is advisable to first excavate the curved tunnel at the outer side, and then construct the curved tunnel at the inner side. The influence of soil loss on the ground disturbance is greater than that of construction loadings. The excessive overcutting gap not only easily induces a sharp increase in the ground vertical displacement, but also may lead to the movement of soil at the inner and middle sides towards the inner side of the curved tunnels, and causes the soil at the outer side to move towards the outer side of the curved tunnels. Remarkably, excessive overcutting gap may lead to large horizontal displacements of the ground surface.

The application of folding arch frames is deemed crucial for unmanned arch frame erection, with the selection of the joint form being a determining factor in the overall mechanical performance of the folding arch frame, particularly in influencing the primary support safety. In light of the geological conditions of the New Wushaoling Tunnel project, three feasible joint forms for folding arch frames were proposed: buckle, adhesive, and interference-fit joints. Numerical simulations were conducted to analyze the arch’s overall mechanical and the joints’ local mechanical performances, aiming to identify the optimal joint form. On-site construction data were collected, and the effectiveness of unmanned arch frame erection was evaluated. The design requirements for the vertical displacement results of the steel arches with different joints were met. The maximum shear stress of the buckled arch frame was found to be the lowest, whereas that of the interference-fitted arch frame was the highest. The local shear stress of the adhesive joints was the lowest, while that of the interference-fit joint was the highest. Considering the material application limitations and calculation results, buckle joints are recommended. Unmanned arch frame erection, compared with manual arch frame erection, can save 66.6% of human resources and reduce the construction time by 33.3% to 50%. Statistical analysis has confirmed that the quality of automated arch construction can be guaranteed.

As the core technology for mechanized installation of tunnel folding steel arch frames, snap-fit connection optimization proves critical in enhancing the load-bearing efficiency of support systems and addressing surrounding rock deformation and instability caused by excavation-induced stress redistribution. Addressing the theoretical gaps in existing research regarding snap-fit selection mechanisms and quantitative evaluation criteria, this study adopts a combined approach of numerical simulation and field monitoring verification based on the excavation compensation concept to systematically investigate the load-bearing characteristics of folding steel arch frames with different snap-fit configurations. Key findings include (1) identification of 20 mm as the optimal joint diameter, where the vertical displacements of Type A and B snap-fit connections reached their minimum values of 43.1 mm and 39.2 mm, respectively; (2) demonstration of significant geometric configuration effects on principal stress distribution, with Type B connections exhibiting 4.5% lower maximum principal stress compared to Type A, effectively mitigating stress concentration; and (3) field monitoring data verification, revealing that Type B connections achieved 15.8% lower stress values than Type A at critical crown sections, satisfying yield strength requirements while demonstrating enhanced resistance to surrounding rock deformation induced by excavation-induced geostress redistribution. These results confirm Type B snap-fit connections as superior structural solutions for folding steel arch frames, thereby facilitating the advancement of mechanized installation technology for tunnel steel arch frames.