Advances in the design and reliability of tunnel boring machines have led to a significant increase in their utilization in recent decades. One consequence has been the increased demand for mechanisation and automation of the entire tunnelling process. It was observed in many tunnel projects that cracking (damage) of the rings has direct influence of the bearing capacity of the concrete lining and represents an important factor for the major loss of lining quality with a detrimental influence on the long-term behavior of segments. A large part of the damage to segments occurs during the construction process, when the TBM occasionally produces large forces and deformations that will lead to failure of the segments due to cracking or compressive failure. This paper presents important aspects of the research that Ed. Zueblin AG performed for the integrated project, Technology Innovation in Underground Construction (TUNCONSTRUCT). New design approaches for TBM tunnels and three-dimensional finite element analyses of a TBM tunnel are shown in this paper. Examples of look-up tables as presented in this paper provide information for the pre-design of segmental linings including a preliminary risk evaluation.