Fractured zones are common unfavorable geological structures that pose significant risks to tunnel stability. To investigate the deformation and failure mechanisms of tunnels intersecting fractured zones with different inclinations, a series of rock specimens containing fractured zones at dip angles of 30°, 45°, 60°, 75°, and 90° were prepared based on a shallow-buried metro tunnel project. Biaxial compression tests were conducted using acoustic-emission (AE) monitoring and digital image correlation (DIC). The results indicate that the presence of a fractured zone substantially weakens the mechanical properties of the specimens. Relative to the specimens with no fracture zones (NF), the peak strength of the F-30°, F-45°, F-60°, F-75°, and F-90° specimens was reduced by 56.7 %, 45.1 %, 38.1 %, 14.9 %, and 9.8 %, respectively. The evolution of maximum principal strain exhibits pronounced temporal asynchrony and spatial asymmetry, while tensile cracking dominates the failure behavior, accounting for more than 80 % of all cracks. Prior to peak strength, the AF parameter drops sharply, and the proportion of shear cracking reaches its maximum. Analysis of the AE peak-frequency distributions reveals two distinct failure types. Type-I specimens (F-30° and F-45°), dominated by low-frequency events (>95 %), fail primarily through slow, large-scale slip along the fractured-zone interface. Type-II specimens (F-60°, F-75°, F-90°) exhibit high-frequency AE events that are 2–5 times more abundant than in type-I specimens, reflecting intense microcrack initiation, propagation, and coalescence driven by stress concentration at the fractured-zone tips and the tunnel boundary. Two characteristic failure sequences were identified: F–T, in which deformation and failure initiate in the fractured zone prior to the tunnel, and T–F, in which tunnel deformation and failure develop earlier than those in the fractured zone. The results indicate that the inclination of the fractured zone governs the tunnel failure mode and alters the sequence of damage evolution. The F-30°, F-45°, and F-60° specimens follow the F–T sequence, whereas the F-75° and F-90° specimens follow the T–F sequence. These findings provide theoretical insights and practical guidance for instability assessment and support design in tunnels crossing fractured zones
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