Objectives When a Tunnel Boring Machine (TBM) crosses deep-buried water-rich fault fracture zones, it often faces an extremely high risk of water inrush, which seriously restricts the safety and efficiency of engineering projects.

Methods This study aims to reveal the evolution law of water inrush disasters during roadway excavation through faults, propose advanced prevention and control technologies, and control water inrush risks. Taking the excavation of a main roadway by TBM crossing a deep-buried fault in a coal mine of the North China-type coalfield as the research background, considering the coupling effect of stress-damage-seepage of surrounding rock, a three-dimensional numerical model of TBM crossing deep-buried fault was established by FLAC^3D software, and the temporal-spatial evolution characteristics and laws of surrounding rock displacement, plastic zone, permeability coefficient and water inflow during the process of TBM approaching the deep-buried fault were simulate and analyze. Based on the disaster mechanism, a comprehensive reinforcement scheme with advanced segmented grouting as the core was proposed.

Results and Conclusions  (1) When TBM approaches the fault, the displacement and plastic zone of surrounding rock behind the excavation face show a significant three-stage spatial differentiation law, While the displacement and plastic zone failure depth of surrounding rock in front of the excavation face increase exponentially, and the permeability coefficient surges by approximately 10⁶ times due to intensified damage, forming a continuous water-conducting fracture network, which ultimately induces the overall instability of surrounding rock and water inrush disasters. (2) The water inflow of TBM surrounding rock increases exponentially with the rise of hydraulic gradient, the critical distance of water inrush is 3.0 m, and the instantaneous water inflow reaches 956.1 m³/h. (3) After implementing the reinforcement of "surface directional drilling + advanced segmented grouting" on the surrounding rock within the affected area of the deep-buried fault fracture zone, the changes in displacement, water inflow, and permeability coefficient of TBM surrounding rock are effectively controlled, ensuring the safety of construction. The research results not only provide a scientific decision-making basis for the safe excavation of TBM but also have important engineering value for enhancing the environmental adaptability of TBM equipment under complex hydrogeological conditions, improving the dynamic early warning system and prevention and control technologies for water inrush disasters.