Damage Evolution of Initial Tunnel Support and Structural Safety of Lining Under Complex Oil–Gas Corrosive Environment

Tunnels excavated in non-coal oil- and gas-bearing strata may experience the seepage and intermittent ingress of an oil–gas–water mixture during construction, creating aggressive corrosive conditions that can compromise the integrity of primary support and the safety margin of the final lining. However, the coupled degradation mechanism of primary support and its cascading effect on lining safety under such conditions remain poorly understood. Based on the Huaying Mountain Tunnel project, this study investigates the corrosion-driven damage evolution of primary support and its implications for the structural safety of the secondary lining under wet–dry cycling exposure. Accelerated wet–dry cycling tests were performed on concrete specimens using an on-site crude-oil–formation-water mixture collected during tunnelling, with exposure levels ranging from 0 to 120 cycles. Laboratory observations were then combined with inverse identification of degradation-dependent material parameters to establish a corrosion-informed mechanical description, which was implemented in numerical simulations for structural response assessment. Results show a staged evolution of mechanical properties, with an initial increase followed by progressive deterioration. After 120 cycles, compressive strength, tensile strength, and elastic modulus decreased by approximately 18.9%, 23.1%, and 17.4%, respectively. Degradation is more pronounced in the corroded zone, with tensile capacity and stiffness deteriorating earlier than compressive resistance. Numerical results indicate that corrosion leads to significant stress redistribution and damage development. The sidewall tensile stress reaches 2.80 MPa after 120 cycles, exceeding the post-corrosion capacity, while the safety factor drops below the code threshold at 90 cycles. The overall safety probability decreases from 1.0 to 0.4, accompanied by a degradation in safety grade from Level I to Level IV. These findings provide a quantitative basis for deterioration assessment, safety verification, and maintenance planning for tunnels subjected to oil–gas corrosive environments.