With the accelerated development of urban underground spaces, prefabricated tunnel linings have become a research focus due to their advantages in construction efficiency and cost effectiveness. However, issues such as stress concentration at joints and insufficient overall stability hinder their broader application. This study investigates a cut-and-cover prefabricated tunnel project in the Chongqing High-Tech Zone through scale model tests and numerical simulations to systematically compare the mechanical behaviors of cast-in situ linings and three-segment prefabricated linings under surrounding rock loads. The experimental results show that the ultimate bearing capacity of the prefabricated lining is 15.3% lower than that of the cast-in situ lining, with asymmetric failure modes and cracks concentrated near joint regions. Numerical simulations further reveal the influence of joint stiffness on structural performance: when the joint stiffness is 30 MN·m/rad, the bending moment of the segmented lining decreases by 37.7% compared to the cast-in situ lining, while displacement increments remain controllable. By optimising joint pre-tightening forces and stiffness parameters, prefabricated linings can achieve stability comparable to cast-in situ structures while retaining construction efficiency. This research provides theoretical and technical references for the design and construction of open-cut prefabricated tunnel linings.

In the rapid process of urban development, prefabricated segmental lining structures have become one of the primary lining forms for super-large section tu