Accurate prediction of rock mass classification is imperative for optimizing safety and cost-efficiency in underground tunnel engineering. Despite its critical importance, conventional single-classification models often exhibit limitations in robustness and accuracy, hindering reliable risk assessment and design optimization. To overcome these persistent challenges, this study proposes a multi-model fusion framework grounded in D-S evidence theory, significantly enhancing classification reliability. Furthermore, an LSTM-based model is developed for ahead-of-face rock class prediction, leveraging geological data from excavated sections. Utilizing 325 field case datasets, unsupervised learning and SMOTE preprocessing were applied, with t-SNE visualization confirming markedly enhanced feature separability. Based on seven key geological indicators, five predictive models spanning classical rock mass rating systems and data-driven machine learning methods were established. These outputs were fused via a D-S evidence theory framework, significantly enhancing classification robustness. Furthermore, hyperparameters of the BP and RF models were optimized via global search algorithms to enhance base classifiers performance. Building upon their test-set metrics, we propose a refinement of the Basic Probability Assignment (BPA) function by integrating precision and accuracy. This modified BPA is adopted as the fusion index with an improved D-S evidence theory framework, establishing a robust rock mass classification model. Validated across three tunnels, the improved D-S model achieved 89.13% accuracy—outperforming all base classifiers. The integrated LSTM predictor further demonstrated robustness to temporal parameter variations. This integrated approach effectively mitigates single-model instability, significantly boosting classification accuracy and robustness. Crucially, its short-range ahead-of-face predictive capability enables proactive support design, enhancing tunnel construction safety.
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