Due to multiple factors influencing the construction safety of TBM hydraulic tunnels, risk assessment is a critical point of a construction management plan to avoid possible risks. In this paper, a safety-risk evaluation index system of TBM construction for hydraulic tunnels is built based on the identification and analysis of possible sources of risk in techniques, geologic, equipment, management, and accidents. Considering the influence of factors such as the experience level and the expertise of decision makers, a combination assignment method of index weights is proposed based on binary semantics. On the basis of a fuzzy normal distribution used as the subordinate function distribution of fuzzy evaluation levels, the subordinate function distribution of fuzzy evaluation levels under multi-level intersection situations is introduced, and a comprehensive evaluation model of safety risks for TBM tunnel construction is built. The validity and practicality of the evaluation model is examined with the combination of a long-distance water conveyance tunnel project. Results show that the construction safety-risk of the TBM hydraulic tunnel project belongs to the middle-high level, and the safety accident risk belongs to the low level. The study provides guidance of evaluation and control of risks for this tunneling construction being successfully completed.

The misalignment of segments in installation is a common issue in the construction of TBM tunnels. This raises a question of whether misalignment affects the operation safety of a hydraulic TBM tunnel. Using a water transfer engineering project as an example, this paper built a three-dimensional finite element model composited with segment, grout layer and surrounding rock for the numerical analysis of the behavior of single-directionally misaligned segments. The crown or invert segment was separately misaligned towards to the center of segment ring in a value of 5 mm, 10 mm, 20 mm, 30 mm or 40 mm. The strength grade of the segment concrete was C50. A weaker surrounding rock composed of V-class rock was considered for the tunnel. The results indicate that the misalignment of the crown or invert segment, respectively, creates the tensile stress in the inner surface of the corresponding segment, the tensile stress will be over the limit of C50 concrete when the misalignment is over 30 mm, indicating a risk of concrete cracking. The contact surfaces of the segment ring basically remain in compression, and the locating pins between the segment rings exhibit an evident increase in tensile stress at misaligned positions. The key points that can be obtained from this study are that a special supervision is needed to ensure the accuracy of segment installation, and strengthening measures are needed for existing misaligned segments.

In the operation period of long-distance water delivery tunnels, safety may be impacted by the risks that arise from different aspects including the complex geological conditions with fault fracture zones and karst caves, the diverse environment affecting structural safety and stability, and the construction defects of tunnels. It is crucial to assess and mitigate potential risks to ensure operation safety. To address this challenge, this study presents a systemic risk assessment for the operation safety of a real project of a water delivery tunnel. The potential risks of this project were first summarized based on the analytical hierarchy process (AHP), and a model that integrates the AHP and fuzzy comprehensive evaluation (FCE) was built to effectively quantify and categorize risks for the project in its operation stage. Results of the assessment indicate that the risk of this tunnel operation can be classified at a moderate grade with a calculted specific risk score of 43.935, with the high-risk factors including segment lining cracking, flow control, and regular maintenance. In response to the high-risk factors, the preventative and control measures are proposed to guide effective risk management. The model presented offers an efficient risk assessment tool for water delivery tunnels, aiding decision makers making more rational management decisions in complex and uncertain environments.

Pea-gravel grouting, which fills the gap between the lining of tunnels and the surrounding rock, is crucial for the structural stability and waterproofing of water delivery TBM tunnels. However, it is prone to defects due to complex construction conditions and geological factors. To provide practical insights for engineers to evaluate grouting quality and take appropriate remedial action during TBM tunnel construction, this paper assesses four types of pea-gravel grouting defects, including local cavities, less density, rich rock powder and rich cement slurry. Detailed numerical simulation models comprising segment lining, pea-gravel grouting and surrounding rock were built using the 3D finite element method to analyze the displacement and stress of the segments at the transition zone between different classes of surrounding rocks, labeled V–IV, V–III and IV–III. The results indicate that a local cavity defect has the greatest impact on the loading response of segment lining, followed by less density, rich rock powder and rich cement slurry defects. Their impact will weaken with better self-support of the surrounding rocks in the order of V–IV, V–III and IV–III. The tensile stress of segment lining is within the limit of concrete cracking for combinations of all four defects when the surrounding rock is of the class IV–III, and it is within this limit for two-defect combinations when the surrounding rock is of classes V–III and V–IV. When three defects or all four defects are present in the pea-gravel grouting, the possibility of segment concrete cracking increases from the transition zone of class V–III surrounding rock to the transition zone of class V–IV surrounding rock.