The construction of cross passages using the tunnel boring machine (TBM) method represents an emerging construction technique with numerous advantages. However, owing to the scarcity of application instances, the safety control methodologies and the regulatory patterns concerning environmental impacts remain inconclusive. In this study, a cross passage excavated using the TBM method-the first of its kind in the Tianjin area-was investigated. We identified the key risk control measures for the construction and analysed the TBM operating parameters, monitored ground and building settlements, and monitored mainline tunnel deformations and mechanical responses, revealing the ground and tunnel structure deformation patterns. The following conclusions are drawn. (1) The ground surrounding the cross-passage break-out opening was stabilised by performing secondary grouting and small-range freezing, and the break-in opening was excavated using a completely enclosed steel sleeve. These measures prevented water and sand inflows during the excavation of the break-out and break-in openings in the silt and silty sand strata. (2) The torsional moment of the cutter disc was large during the break-out phase. Break-out mainline tunnel displacement monitoring data indicated that the thrust had a significant effect on the mainline tunnel during the break-out phase. (3) The TBM tunnelling caused ground loss. The ground settlement exhibited a U-shaped distribution along the cross-passage axis, with the maximum settlement being 10 mm. (4) During the break-out phase, the deformation of the break-out mainline tunnel exhibited a duck-egg-shaped distribution. The clearance convergence of the break-out mainline tunnel was within ± 4, and the clearance convergence of the break-in mainline tunnel was controlled within ± 1 mm.
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