July 3–7, 2017 th

Annual Meeting
ICOLD – CIGB

PRAGUE
2017

Prague, Czech Republic of International Commission on Large Dams

Tailings dam design - technology update (ICOLD bulletln)

Harvey McLeod1,a, Annika Bjelkevik2,b

1Klohn Crippen Berger Ltd., Vancouver, Canada

2Tailings Consultants Scandinavia AB, Stockholm, Sweden

ahmcleod@klohn.com
bannika.bjelkevik@tailings.se

ABSTRACT
Mine tailings are produced after crushing, grinding and processing, to recover the ore minerals. This
paper will focus on the management of tailings and the changes in evolving technologies that also
continue to be a focus of the regulatory and environmental communities.

The Bulletin acts as a reference guideline to improve knowledge on developments and trends in
design, operation and closure of tailings dams for both tailings dam engineers and a wide audience of
stakeholders: owners, regulators, communities etc. While it is not a design guide document, it does
serve as a technology update to improve the practice of tailings dam engineers. The authors
emphasize that design and operation of tailing dams should be performed by qualified and
experienced professionals and that all tailings dam designs are different. Tailings dam designs need to
incorporate the site specific conditions, such as climate, physiography, geochemistry, geomorphology,
mining processes, etc. and the application of selected technologies plays an important role in
developing safe, sustainable tailings dams.
The Bulletin, and this paper, will cover three main subjects: tailings properties, tailings technologies
and design practices, with examples and good practices will be discussed.
 July 3–7, 2017 th Annual Meeting
ICOLD – CIGB

PRAGUE
2017

Prague, Czech Republic of International Commission on Large Dams

1. INTRODUCTION

Mining is a major international industry which produces large volumes of mine waste rock and tailings.
This paper will focus on the tailings, which is removed after crushing, grinding and processing to recover
the ore minerals. The focus of this paper is on the design of dams and storage of tailings from a technical
perspective. Management related aspects, which are equally important, are not specifically addressed
in this paper.

The overall focus on tailings management continues, due in part to the recent significant tailings dam
failures and the potential for high environmental, social and economic risks. The management of tailings
is, therefore, crucial and many books, technical papers etc. have been published on the topic. The
principals of sound engineering of tailings dams are commonly available but need to be applied through
the life cycle of a tailings dam, from early construction through to decommissioning and final closure.
This paper will summarize the coming ICOLD Bulletin on Tailings Dam Design – Technology Update.
The Bulletin is meant to act as a reference guideline to improve knowledge on developments and trends
in design, operation and closure of tailings dams for both tailings dam engineers and a wide audience
of stakeholders: owners, regulators, communities etc. While it is not a design guide document, it does
serve as a technology update with the objective to improve the practice of tailings dam engineers. The
Bulletin, and this paper, will cover three main subjects; tailings properties, tailings technologies and
design practices, where examples and good practices will be given.

All mining operations, and thereby tailings operations, are unique. There is no “one solution fits all”
available. Tailings dam designs need to incorporate site specific conditions, such as climate,
physiography, geochemistry, geomorphology, mining processes, etc. and the application of selected
technologies plays an important role in developing safe, sustainable tailings facilities. Some design
drivers are:

 Increased production rates and increased tailings volumes as mines get larger;
 Mines can be in remote and very challenging environments;
 Increased requirements to reduce, or minimize, the environmental footprint, for example
reduce consumption of water and energy as well as land disturbance;
 Increased requirements to minimize the impact on ground- and surface waters;
 Reduce dust from mining operations; and
 Available technologies and combinations of technologies.

These have for example increased the use of filtering tailings (which reduces the water content to a
minimum, limiting the consequences in case of failure) and increased the height of tailings dams to limit
the footprint (which may increase the risk and the consequence of failure).

2. TAILINGS PROPERTIES

The ore mineralogy as well as the processing methods will have an impact on the tailings properties.
Processing of tailings may also include thickening, sulphide removal, separation of slimes and sand
fractions which also impact the tailings characteristics. The geotechnical and geochemical properties of
the tailings have a major influence on the selection and optimization of a tailings management facility
(TMF), the design of the containing structures, i.e. the tailings dam, as well as the tailings transport and
deposition method.

The geotechnical properties of the tailings affect the performance of the TMF both during operation and
post closure. Material characterization forms a fundamental part of the design, as well as being essential
during operation to ensure that the assumed parameters for the TMF and the containing structures are
being achieved.

Characterization for geochemical purposes involves the assessment of neutral leaching and acid
generation potential as well as the identification of any hazardous/dangerous substances. This will
however not be discussed in this paper, but is referred to in the upcoming ICOLD Bulletin.
 July 3–7, 2017 th Annual Meeting
ICOLD – CIGB

PRAGUE
2017

Prague, Czech Republic of International Commission on Large Dams

Tailings normally have similar properties to normal geological soils, but the processing, the
transportation, the deposition and the geochemical characteristics may impart non-standard properties
to the material both at particulate and mass deposition level. Tailings properties differ, however,
significantly depending on the orebody mineralogy and, the processing and/or degree of grinding in the
milling circuit. High clay contents or the presence, sometimes in relatively small quantities, of
montmorillonite and bentonitic clays, significantly influence the consolidation and engineering
properties. Table 1 presents a summary of tailings classifications into 5 different categories. The
classification is similar to those presented by Fell et al. (2005) and Vick (1990), however, the categories
have been structured to include the continuum from coarse tailings through to ultra-fine clay tailings.

Design parameters derived from geotechnical testing are crucial in confirming the size and configuration
of the TMF, the main embankment rate of rise, the required sequential construction intervals, the
associated project economics for a defined project production (tonnage), and the closure properties.
Geotechnical analysis is also essential in assessing the benefits of any basin and embankment drainage
system requirements, as well as in confirming transport/depositional methodology.

Table 1. Summary of Tailings Types and Geotechnical Classification

Tailings Description (compare Example of mineral/ore

Symbol
Classification
Coarse Salt, mineral sands, coarse coal
tailings
C Silty SAND, non-plastic,
rejects, iron ore sands,
Hard Rock Copper, massive sulphide, nickel,
tailings
HR Sandy SILT, non to low plasticity
gold,
Altered Rock Sandy SILT, trace of clay, low Porphyry copper with hydrothermal
tailings
AR plasticity, bentonitic clay content alteration, oxidized rock, bauxite
SILT, with trace to some clay, low Bauxite (red mud), Fine coal
Fine tailings F to moderate plasticity rejects,
Silty CLAY, high plasticity, very oil sand (mature fine tailings),
Ultra Fine
tailings
UF low density and hydraulic phosphate fines; some kimberlite
conductivity and coal fines

2.1 Laboratory Properties

The laboratory testing program for tailings has to consider the proposed milling process, the deposition
plan and the influence of segregation during deposition. The following sections provide typical
geotechnical parameters for various types of tailings, which can be used as indicative numbers before
comprehensive laboratory and field testing can be carried out.

The geotechnical properties of the tailings are significantly influenced by the index properties which
include: gradation of the tailings, the plasticity (Atterberg Limits) and the clay percentage and
mineralogy, as illustrated in Figure 1.,Figure 2, and Figure 3, respectively
 July 3–7, 2017 th Annual Meeting
ICOLD – CIGB

PRAGUE
2017

Prague, Czech Republic of International Commission on Large Dams

Figure 1. Typical Gradations for Tailings Types

Figure 2. Plasticity Chart for Tailings Types

The behavior, and hence classification, of different types of tailings can be characterized with the simple
“jar settling test”, where tailings are placed in a 2 L beaker at a range of initial percent solids by weight
and the rate of settling is measured with time. Figure 4 presents typical rates of settling for different
types of tailings. Note that the % solids in the chart does not directly account for the specific gravity of
the solids, and higher specific gravity solids would result in higher % solids for similar settling times.
 July 3–7, 2017 th Annual Meeting
ICOLD – CIGB

PRAGUE
2017

Prague, Czech Republic of International Commission on Large Dams

Figure 3. Activity Chart for Tailings Types

Figure 4. Jar Settling Test – Percent Solids of Settled Tailings versus Time

The consolidation properties of the tailings influence the time for consolidation and the final density,
which is reflected in the void ratio, of the settled tailings and is illustrated on Figure 5.

Figure 5. Consolidation Properties for Tailings Types

 July 3–7, 2017 th Annual Meeting
ICOLD – CIGB

PRAGUE
2017

Prague, Czech Republic of International Commission on Large Dams

An approximate correlation with tailings types and hydraulic conductivity with the % fines (percentage
passing 75 micron sieve size) is shown on Figure 6. Caution, however should be used with respect to
percentage and type of clay, which significantly reduces the permeability.

Figure 6. Hydraulic Conductivities for Tailings Types

The viscosity and yield stress of the tailings is important in assessing tailings transport properties and
the thickening properties of tailings. Figure 7 presents the typical yield stress for various levels of
thickening for the tailings types versus the percent solids by weight. Note that the percent solids content
is also dependent on the specific gravity of the solids, which would increase the percent solids in a
relative sense to those shown.

Figure 7. Yield Stress versus Percent Solids for Tailings Types and Thickener Types

2.2 Other Types of Tailings Tests

Project specific laboratory tests have been developed to attempt to simulate the conditions encountered
in the field. Examples of these include:

 Drained settling tests are intended to simulate the effect of drains under or within the
deposited tailings. The test is carried out in the laboratory using a cylindrical glass tube with
a drainage system at the bottom.
 Evaporation tests are intended to simulate the effect of air drying in arid climates. The test is
carried out in the laboratory using heat lamps calibrated to evaporation rates and
measurements of moisture content with time and depth are recorded, along with the density
of the consolidated tailings.
 Non-segregating tests are carried out to determine the percent solids by weight in which the
tailings will behave as a non-segregating mass during deposition.
 July 3–7, 2017 th Annual Meeting
ICOLD – CIGB

PRAGUE
2017

Prague, Czech Republic of International Commission on Large Dams

2.3 In Situ Properties

The in situ properties of deposited tailing can, to a large degree, be extrapolated from laboratory testing
and there is a significant amount of field data from mining operations around the world that provides
insight into the behavior of deposited tailings in the field. This section summarizes the key aspects of
field behavior and discusses the controlling factors. In addition to the response of various types of
tailings (Figure 8), the field behavior is significantly influenced by the percent solids by weight of the
tailings slurry (i.e. pulp density) and the deposition method. Additionally, the climatic conditions, such as
in desert versus cold climates influence the in situ properties. In the following paragraphs some
relationships of field data is presented.

Figure 8. Typical Beach Slopes for Tailings Types and Thickening Process

The in situ properties are influenced by segregation that may occur during deposition. For example,
segregation of a hard rock tailings could result in zones of coarse tailings grading to altered rock tailings
or fine tailings. The scale of the tailings facility is also important when extrapolating laboratory data to
the field. For example, beach slopes derived from laboratory or bench scale tests on filtered tailings
typically give high beach slopes, up to 6%. however, as shown on Figure 8 beach slopes in practice do
not support the laboratory predictions at slope lengths of over several hundred meters.

The hydraulic conductivity of tailings in the field is also influenced by the variations in deposition density,
milling processes, ore mineralogy, etc. often resulting in a complex interlayering of various gradations
and types of tailings which introduce anisotropy into the hydraulic conductivity and consolidation
behaviour.

The behaviour of tailings under high stresses is becoming increasingly important as dams become
larger. For example, recent research suggests that loose tailings at high stresses become less brittle
and behave more as a normally consolidated clay.

3. TAILINGS TECHNOLOGIES

This section provides a description of the various technologies that are used to produce and deposit
tailings. The range of technologies includes equipment, tailings segregation, and design methods. The
technologies for control of the water component of tailings slurry range from the historical use of
spigotting and along the continuum of reducing the water content with cyclone, thickener and filtration
equipment. The segregation of tailings ranges from the conventional use of cyclones to the application
of mill processing alternatives to separate tailings based on geochemical properties. Design
technologies continue to evolve from which the geotechnical properties of the tailings can be taken into
advantage and incorporated into dam design.
 July 3–7, 2017 th Annual Meeting
ICOLD – CIGB

PRAGUE
2017

Prague, Czech Republic of International Commission on Large Dams

3.1 Spigotting and Cycloning

Spigotting of tailings, which is primarily considered for upstream constructed tailings dams, is used to
increase the segregation of coarser particles near the dam crest, which improves drainage, and to
develop a more uniform zone of tailings within the structural zone of the dam (see Figure 17). Figure 9
shows an example of multi-point spigot deposition. Cycloning of tailings was developed in the 1960’s
and continues to be a major component of tailings dams, particularly for the large porphyry copper
mines. Cycloning produces a sand which can be used for the construction of a centerline dam and can
also be used for downstream and upstream dams. Figure 10 shows a typical cyclone arrangement,
whereby the cyclone underflow pipeline is directed to cells located on the downstream slope, where the
sand tailings are compacted, and the cyclone overflow forms a beach upstream of the dam crest.
Cycloning of altered rock tailings typically requires hydro-cyclones and there is a lower sand recovery
rate. It is generally not practical to cyclone finer tailings.

Figure 9. Deposition by Spigotting Figure 10. Typical Cyclone

Arrangement on Crest of Dam

3.2 Thickening
Thickening has been used to improve water recovery from tailings streams since the mid 1990’s. The
solids content of the thickened slurry is dependent on the tailings type and the thickening process
adopted. The density of the tailing slurry can vary significantly depending on the type of ore and the
processing methods. For most metal mines, the density of the tailings is typically on the order of 30
percent solids by weight. Thickening the tailing slurry as part of the process plant operation using
conventional thickeners has become a common practice over the last few decades. Additionally, over
the last couple of decades, a range of new thickeners have been developed and the thickening
technology has improved to include production of increasingly higher percent solids with the use of: high
rate, high compression and ultra-high rate (deep cone paste thickeners). The achieved densities are
typically between 55% and 70% solids by weight.

The range of yield stress of the various types of tailings and types of thickeners is presented on Figure 7.
The “theoretically” possible percent solids have been hampered by variations in ore mineralogy,
processing variability, flocculent response, and human controls, and as a result most of the higher
density thickeners typically achieve lower percent solids than predicted.
 July 3–7, 2017 th Annual Meeting
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2017

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Figure 11. High Rate Thickener

Figure 12. Deep cone thickener

3.3 Filtered Tailings

Filtering of tailings for land disposal gained some popularity in the 1980s, however due to the significant
capital costs of the filtering equipment and the operational costs (power consumption), filtering of the
tailings was not feasible for most operations. With the improvement in the efficiency of the filtering
equipment and the focus on reduced water consumption, together with the reduced risk of physical
stability, the interest towards tailings filtering has significantly increased in recent years.

Filtered tailings technologies can be classified into two general categories: vacuum filters and pressure
filters, which vary with respect to the moisture content of the filtered tailings. Vacuum filters (see Figure
13) typically produce a saturated tailings product with a moisture content that can be of the order of 5%
or more over the optimum proctor moisture content required for compaction. Pressure filters (see Figure
14), however, may achieve much lower moisture contents and typically are required if it is necessary to
compact the filtered tailings for trafficability or for static or seismic liquefaction stability. There are
numerous other types of filters, such as drum filters, disc filters, membrane filters, tower filters, screw
press filters, etc. and manufacturers continue to innovate and improve filter systems to increase their
applicability and reliability and to accommodate higher tonnage production rates.
 July 3–7, 2017 th Annual Meeting
ICOLD – CIGB

PRAGUE
2017

Prague, Czech Republic of International Commission on Large Dams

Image reference: (OutoTec Laros RTTM)

Figure 13. Schematic of a Horizontal Vacuum Belt Filter

Image reference: (FLSmidth 2014)

Figure 14. Horizontal Pressure Filter

3.4 Other Technologies

Other technologies continue to evolve and to be considered either as a component of a tailings
management system or dam design, or for site specific applications. The relatively recent practice of
sulphide separation with a flotation circuit in the process plant can produce a tailings product with a low
acid rock drainage potential. The sulphide tailings, which is typically 10%, and up to 40%, of the total
tailings, can then be managed separately.

The integration of tailings management with mine waste rock management is important and can be used
to reduce costs and risks. Co-mingling options consider mixing of tailings and waste rock together prior
to placement or with special placement techniques that increase mixing of the materials. Co-disposal
techniques may consider placement of acidic mine rock with the tailings or deposition of tailings within
cells constructed within the waste rock storage area. Co-mingling has had little practical success for
most mining operations, whereas co-disposal of acidic rock in the TMF continues to gain increased
acceptance.

In arid climates, air drying of tailings is commonly used to increase consolidation of the tailings with the
use of cells which allow sufficient time to dry prior to placement of the next lift. Cell construction is also
used in arid climates to limit the evaporation losses from the wetted beach surfaces.

4. DESIGN PRACTICES

Engineering design of tailings dams started in the 1960’s with the application of geotechnical principles
and dam technologies developed from the water dam community. In parallel to these designs, upstream
tailings dam construction techniques, which have historically been used for over a hundred years, have
evolved with improved construction practices and improved understanding of the strength limitations
related to static and dynamic liquefaction. Dam designs continue to consider the traditional downstream,
 July 3–7, 2017 th Annual Meeting
ICOLD – CIGB

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2017

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centerline and upstream geometries. More recently, high density paste piles and filtered tailings piles
are being considered as alternatives to conventional dam construction and tailings management plans.
Dam design needs to be integrated with the geochemistry of the tailings and the requirements for
environmental control, which may, for example, require saturation to mitigate acid rock drainage or dust
control. Design of the tailings dam needs to incorporate the requirements for transition to long term
closure, with the objective of minimizing the long term risks of physical, geochemical and ecological
stability.

4.1 Downstream and Centerline Dams

Downstream dam designs are typically very similar to water dam designs (see Figure 15), however for
tailings dams it is preferred to have the low permeability zone in the upstream slope of the dam. This
takes advantage of the gradient reduction provided by the tailings placed against the core zone and the
crack filling properties of the tailings. Whereas placement of rockfill between the core zone and the
tailings typically ensures that the full hydraulic head and gradient is against and across the core zone.

Centerline dams are a variation of the downstream dam. In this case the central core zone is supported
by the tailings and a localized zone of fill placed on top of the tailings as shown on Figure 16. As for
downstream dams, the upstream core support zone should preferentially use cyclone tailings to reduce
hydraulic gradients through the core zone.

Figure 15. Downstream Constructed Dam

Figure 16. Centerline Constructed Dam

4.2 Upstream Dams

Upstream constructed tailings dams rely on the spigotted tailings to provide structural support for the
dam. While the use of controlled spigotting and deposition planning can improve the structural stability,
the tailings are typically loose and contractant. Consequently, the used of undrained shear strength
analysis for both static and dynamic stability are important criteria that control the dam geometry.
Stability can also be increased with the use of horizontal drains and compaction of spigotted beaches.
 July 3–7, 2017 th Annual Meeting
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2017

Prague, Czech Republic of International Commission on Large Dams

Figure 17. Upstream Constructed Dam

4.3 Dams for High Density Thickened and Paste Tailings

High density thickened and paste tailings piles continue to be promoted as opportunities to reduce the
height of the impounding dam and to increase the recovery of water in the process plant. Practical
experience with these projects suggest that the beach slopes, as shown on Figure 8 of this paper, are
generally less than predicted, particularly for longer distance slopes. The management of surface runoff
water from the tailings piles typically require external water ponds to attenuate seasonal and flood flows
for controlled recycling of water and/or environmental release. Environmental controls for the piles may
still require liners and water treatment and, in some cases, potentially flooding on closure to mitigate
acid rock drainage.

4.4 Design Considerations for Filtered Tailings

Filtering of tailings requires considerable mechanical plant and financial investments to dewater the
tailings, which in conjunction with operating and environmental requirements need to be compared with
other tailings management technologies. The filtered tailings product is typically saturated and, if placed
without compaction, contractant. Consequently, the stability of the pile needs to consider undrained
strength analysis and the potential for static or dynamic liquefaction. If required for structural stability,
the outer shell of the filtered tailings pile may require compaction and/or placement of drainage layers.
Placement of filtered tailings considers the practicality and logistics of placement in various climate
conditions. Environmental controls for the piles may still require liners and water treatment, particularly
if the tailings are potentially acid generating or in a sensitive environmental setting.

4.5 Other Design Practices

The designs of tailings management facilities are very site specific and dependent on a wide set of
variables. Consequently, unique tailings management facilities continue to evolve to suit that the
applicable site constraints and opportunities. These may include variations and combinations of the
technologies outlined in this paper and the different dam design sections and variable tailings deposition
plans and water management.

5. CONCLUDING REMARKS

The authors emphasize that design and operation of tailing dams should be performed by qualified and
experienced professionals and that all tailings dam designs are different. Tailings dam designs need to
incorporate the site specific conditions, such as climate, physiography, geochemistry, geomorphology,
mining processes, etc. and the application of selected technologies plays an important role in developing
safe, sustainable tailings facilities. The ICOLD Bulletin is expected to be published in 2018 and will
provide additional information and details on the technologies discussed in this paper.

6. REFERENCES

Fell, R., MacGregor, P., Stapledon. D., and Bell G. Geotechnical Engineering of Dams. Leiden,
Netherlands : A.A. Balkema, 2005.

Vick, Stephen G. (1990). Planning, Design, and Analysis of Tailings Dams. BiTech Publishers Ltd.,
Vancouver, Canada. Pp42-60.