Completely decomposed granite
exhibits strong cohesiveness because of its high fine-particle content, posing a
major challenge to earth pressure balance shield tunneling in metro projects in
the southeastern coastal region of China. This material tends to adhere to the
cutterhead and form mud cakes, which can sharply increase cutterhead torque,
hinder muck discharge, and reduce excavation efficiency. In severe cases,
frictional heating may solidify the mud cake, forcing shutdowns for chamber
opening and creating substantial economic and safety risks. Foam conditioning
is an effective approach for treating such cohesive strata. However, existing
studies lack a robust strategy for systematically optimizing foam components
for completely decomposed granite strata. As a result, it is difficult to
balance multiple objectives, including foaming performance, conditioning effectiveness,
and cost-effectiveness. In addition, the complex interaction effects within
multicomponent foam systems have often been overlooked. To address this issue,
this study employed response surface methodology (RSM) combined with central
composite design (CCD) to develop a predictive model for foam performance. The
independent variables were the anionic surfactant sodium alpha-olefin sulfonate
(AOS), the nonionic surfactant alkyl polyglucoside (APG), the foam stabilizer
xanthan gum (XHG), and the inorganic dispersant sodium hexametaphosphate
(SHMP). In
terms of performance evaluation, foaming ability was characterized by the foam
volume measured with a modified Ross–Miles foam tester. Foam
stability was assessed using both foam half-life and the 5-min defoaming rate.
The ability to reduce soil adhesion was quantified by the interfacial adhesion
force measured with a modified Yida conical bao pull-off tester.
Multi-objective decision-making was performed using the desirability function
approach, and the optimal compound formulation was identified as the Fuyan-1S
foaming agent (FY-1S), containing mass percentage contents of AOS, APG, XHG and
SHMP are 4.18%, 1.59%, 0.16% and 0.95%, respectively. Laboratory tests
showed that the FY-1S foaming agent outperformed three selected commercial
foaming agents in key properties, particularly stability and reduction of
interfacial adhesion. Field engineering validation was conducted in an EPB
shield tunneling section of Xiamen Metro Line 3. By comparing
the conditioning effects of FY-1S with those of commercial foaming agents, this
study systematically evaluated both soil properties, including interfacial
adhesion force, undrained shear strength, and vertical slump, and shield
tunneling parameters, including cutterhead torque, total thrust, advance rate,
and chamber pressure. The results demonstrated that FY-1S effectively improved
soil workability and significantly reduced soil mechanical strength, cutterhead
torque, and excavation resistance, thereby enhancing shield tunneling
efficiency and operational adaptability.