Development of a fully prefabricated subway station using scale experimental modeling

The widespread adoption of prefabricated structures faces two critical challenges: ensuring reliable connection performance while maintaining assembly efficiency, and meeting the stringent precision requirements for mechanical connectors during installation. To address these issues, this study develops an innovative steel connector mechanical system for prefabricated subway stations and establishes a comprehensive evaluation methodology integrating assembly process simulation with structural performance assessment. Through scaled model tests combining static and cyclic pushover loading, the research demonstrates that the proposed connector successfully reconciles assembly efficiency with structural reliability, showing minimal displacement during assembly and substantial load-bearing capacity in service conditions. The prefabricated system exhibits excellent seismic performance through a controlled yield mechanism where localized damage at frame corners protects critical joints, maintaining structural integrity up to interstory drift ratios exceeding the limit of 1/250 specified by the Chinese code GB 50909–2014. These findings provide both a validated technical solution and a systematic evaluation framework for advancing prefabricated underground construction.