A methodology for designing a tunnel support system according to the actual ground conditions and the critical behaviour types is analysed in this paper. The methodology is justified with the principles of the New Austrian Tunnelling Method that incorporates the top heading and bench method. The role of the geological material and its implication in tunnel design, reinforced with advances in site investigation methods, cannot be based solely on the development of the geotechnical classification systems and the consequent quantification of the rock masses. Support requirements for rock masses with equal classification ratings can be different. The procedure presented in this study cannot bypass the geological and/or in situ characteristics dictating or influencing the tunnel behaviour compared with a standardised classification that could miss the specifics and particularities of and around a tunnel section. The step-by-step procedure is applied in a tunnel excavated in tectonically disturbed heterogeneous flysch sediments in Serbia. The complex structure of these materials, resulting from their depositional and tectonic history that includes severe faulting and folding, presents a challenge to geologists and engineers. The possible ground types are evaluated, and then, combined with the factors of the tunnel geometry, the primary stress condition, and the water conditions, several behaviour types are considered. These classified behaviour types, followed by the suitable mechanical properties that are required for effective tunnel engineering design, are the basis for the numerical design of the appropriate primary support measures to achieve stable tunnel conditions. The twin-tube, two-lane highway tunnel was successfully constructed without significant problems.
