• A longitudinal vulnerability-based method is proposed to assess shield tunnel safety under adjacent foundation pit excavation, incorporating geological uncertainties via random field theory.
• The maximum longitudinal deformation is identified as the most effective control index for ensuring tunnel usability and safety, compared with circumferential opening and bending moment.
• Tunnel vulnerability decreases nonlinearly with increasing tunnel and subgrade stiffness, with subgrade stiffness having a more pronounced effect.
• Active reinforcement of the substratum is more effective in reducing failure risk than passive reinforcement of the tunnel structure.
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