Research and Application of a Prefabricated Spatial Reticulated Shell Support System for Large Cross-Section Tunnel in a Complex Urban Environment

To solve the technical problems of slow construction progress, low mechanization and high risk of shallow buried large cross-section tunnels in a complex urban environment, a series of spatial reticulated shell (SRS) support structures are developed in this paper. Moreover, the equipment of a multifunctional operation trolley is developed to install the SRS arch, and the construction technology system of the prefabricated SRS structure is proposed for a large cross-section tunnel. Therefore, the deformation characteristics of the end-plate joint component and jointless component are clarified by laboratory experiments. The construction mechanics’ simulation of the SRS arch is performed to obtain the tunnel deformation and structure stress based on the tunnel project of Panyu Square Station of Guangzhou Metro. A field application of the prefabricated SRS arch is carried out to realize the mechanized construction operation. The obtained results reveal that the end-plate joint component has better ductility, and its ultimate bearing capacity is basically consistent with the jointless component. The SRS arch can effectively control the deformation of the surrounding rock, improve the stress state of the structure, and reduce the plastic zone of shotcrete by numerical simulations. The overall stress of the SRS arch by field measurement represents the characteristics of “bigger on the upside and smaller on the downside” and “uneven symmetry”. Additionally, the successful application of the prefabricated SRS arch provides a scientific reference for mechanized construction of large cross-section tunnels.