This study describes the causes of shield tunnel segment cracks and alignment issues during shield tunnelling. The study was conducted in Down Town Line 3 (DTL3) contracts 926 and 927 twin tunnel projects in Singapore. It is revealed that these issues arose when Tunnel Boring Machine (TBM) shoving on curve alignment though TBM is designed with articulation, which allows the machines to handle tight curves with ease. The study focused on how construction methodology affects the quality of tunnelling in terms of alignment and segment cracks. It was found that the clearance between the tail shield and tunnel lining was not maintained during mining. As a result, the tail shield exerts stress on the segments and causes cracks. In addition, the tunnel alignment deviated from pre-designed alignment, which directly affects the safety and durability of the shield tunnel. This study concludes that a proper selection of ring type “right lead” or “left lead” and the appropriate key selection, along with the skill of the workers, significantly solve segment cracks and alignment issues.
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