Currently, tailings storage facility projects worldwide face three major issues due to incomplete design and construction qualifications: unreasonable design, non-standard construction, and inadequate supervision. These problems severely impact the safe operation of projects. In response to these pain points, Xinhai provides full-process tailings storage facility (TSF) services covering design, construction and supervision. This systematic approach solves clients’ challenges and ensures the safety, compliance, and sustainability of the project.
Three Major Pain Points in TSF Projects Worldwide VS Xinhai's TSF Service:
Xinhai’s integrated TSF solution delivers full-process coverage across design, construction, and intelligent supervision. With tailor-made TSF design, standardized construction management, and smart full-process oversight, we ensure safety, efficiency, and long-term stability from start to finish.
Tailor-made TSF Design: Our design team, composed of over 100 engineers specializing in structure, hydrogeology, environmental protection, and tailings processing, offers tailored solutions based on site-specific geological conditions, tailings properties, and hydrometeorological factors. We provide a comprehensive design service from site selection, dam structure design, flood drainage system layout to water recycling systems.
Standardized Construction Management: With Class-A Qualification for General Contracting of Mine Construction Projects, Xinhai is capable of undertaking the construction of tailings storage facilities ranging from Class I to Class V. Our in-house construction team, with over 100 members during peak periods, has rich experience in tailings storage facility construction, covering key processes like embankment layer compaction, geomembrane installation, and flood drainage system setup, ensuring traceable and inspectable workflows for quality control.
Full-Process Intelligent Supervision: Xinhai possesses comprehensive management capabilities for every phase of tailings storage facility construction, supported by a professional project management team. Our team oversees project management, construction management, safety management, and environmental management, efficiently coordinating all resources to ensure timely, successful project completion and compliance with operational standards.
Xinhai is capable of undertaking the general contracting projects for tailings storage facility ranging from Class I to Class V, with integrated services in design, construction, and operation. Xinhai boasts a strong team of over 100 design engineers, numerous project management personnel, and more than 300 experienced construction workers. With over 100 sets of specialized construction machinery and equipment, we are fully equipped to meet the diverse needs of tailings storage facility construction, ensuring timely and high-quality project delivery. Our services include TSF Design, TSF Construction and TSF Operation & Supervision.
2.1 Tailings Storage Facility Design
Xinhai’s design team covers a wide range of disciplines, including civil engineering, mining, mineral processing, tailings management, power systems, and automation, with over 100 specialized design professionals. We tailor our designs based on project-specific geological conditions, tailings characteristics, and environmental requirements. Our comprehensive design services optimize key elements such as the initial dam, drainage systems, tailings transport systems, seepage control, water recycling, and monitoring systems. We also provide feasibility reports, preliminary designs, safety facility designs and construction drawings to ensure smooth project initiation and successful safety production license applications.
Site Selection and Feasibility Study: The selection of a tailings storage facility site requires comprehensive consideration of natural factors such as topography, geology, hydrology, and meteorology, as well as safety distances from residential areas and critical infrastructure. The preferred sites are valleys or depressions with small catchment areas, minimal engineering work, and sufficient storage capacity. The geological structure of the site must be stable, avoiding fault zones and areas prone to collapse. Additionally, it’s essential to ensure that the tailings storage facility is located at a safe distance from surrounding residential areas and industrial facilities, to prevent accidents like dam failures that could lead to casualties or property damage.
Preliminary TSF Design: After the approval of the feasibility study report, Xinhai initiates the preliminary overall design of the tailings storage facility based on geological, hydrological, and resource conditions. Including:Tailings Conveying Path Design, Dam Location and Structure Design, Storage, Capacity Design, Drainage and Seepage Control System Layout, Inlet and Outlet Design and Observation and Monitoring Point Layout.
TSF Safety and Protection Facilities Design: Xinhai strictly follows national standards and project risk classification requirements to comprehensively plan the tailings storage facility safety and protection system. This includes monitoring, drainage, seepage control, seismic protection, fire prevention, and emergency facilities, including Monitoring System Design, Dam Drainage System Design, Seismic, Fire, and Anti-Sliding Safety Design, and Safety Passage and Emergency Facility Setup.
2.1.1 TSF Construction Drawing Design
Construction drawing design is a crucial link in tailings storage facility construction, bridging planning and on-site implementation. Xinhai provides a complete set of construction drawings and organization plans during this phase, including: Construction Sequence and Organization Flowchart, Dam Body Structural Drawing, Foundation Treatment Drawing, Seepage Control Structure Drawing, and Drainage System Drawing.
Through systematic and detailed construction drawing design, Xinhai ensures that the project is executed based on reliable plans, with full control over safety, quality, and progress throughout the construction process.
2.1.2 Tailings Storage Facility Construction
Xinhai has the capability to undertake tailings storage facility EPC projects and with the Class-A Qualification for General Contracting of Mine Construction. Only around 50 private companies in China have received this qualification. The company is capable of undertaking tailings storage facility construction projects from Class I to Class V, covering the entire process from construction organization, civil engineering implementation, to equipment installation.
Xinhai holds the Class-A qualification for general contracting of Mine Construction, a certification held by only about 50 private companies in China. Xinhai can undertake EPC projects for tailings storage facilitys of all classes (I to V). During construction, Xinhai strengthens safety management and quality control through scientific construction organization design, progress monitoring, and quality management, ensuring that projects are completed efficiently, safely, and in compliance with regulations.
Xinhai boasts a dedicated team of project managers, over 300 experienced construction personnel, and more than 100 sets of specialized construction machinery (excavators, dump trucks, concrete transport vehicles, pump trucks, batching plants, rollers, graders, loaders, etc.), providing solid support for the construction of various types of tailings storage facility.
Tailings Storage Facility Dam Construction: The tailings storage facility dam serves to block the tailings and water, creating the storage capacity to hold the tailings and prevent leakage that could lead to safety incidents. Xinhai offers three types of dam construction based on different geological conditions and project requirements: Earth Dam Construction, Rockfill Dam Construction and Earth-Rockfill Composite Dam Construction.
TSF Supporting Facility Construction: Structural and Civil Engineering Facilities, Water Management Facilities, Supporting Equipment, Monitoring and Automation System Construction and Office and Living Facilities.
During the construction phase, the automation monitoring system is deployed, with sensors such as displacement meters, piezometers, and rain gauges installed to monitor dam deformation, seepage lines, and storage water levels 24/7. After delivery, long-term operation and maintenance services are provided, including regular safety assessments and the use of big data analysis to predict potential risks, ensuring technical support for the entire lifecycle management of the tailings storage facility.
Tailings Storage Facility Construction Process:
Excavation – Site leveling and excavation of dam foundation trench.
Reinforced Concrete Pouring – Concrete pouring for dam body, spillway tower, drainage pipes, and other structures.
Earth and Rock Filling – Dam construction, road building, and backfilling.
Geosynthetic Materials Installation – Seepage control, filtration, and reinforcement for the dam body.
Masonry Work – Stone masonry for slope protection, retaining walls, drainage ditches, and other structures.
After the tailings storage facility is put into operation, Xinhai provides systematic operation, maintenance, and supervision services to ensure the safety of the dam structure. This guarantees the safe, stable, and environmentally compliant operation of the tailings storage facility throughout its entire lifecycle, minimizing potential risks and liabilities for the owner during operation.
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3.1 TSF Intelligent Monitoring System
Xinhai deploys an online safety monitoring system for tailings storage facility, installing electronic monitoring instruments, sensors, and communication facilities on the tailings storage facility area, dams, drainage systems, and other structures. Through engineering surveys, network communication, and computer technology, the system enables 24/7 automatic monitoring, surveillance, analysis, and early warning of tailings storage facility safety. Key data monitored include dam displacement (both surface and internal), infiltration line (seepage) monitoring, dry beach length, storage water level, and rainfall.
3.2 Long-Term TSF Operation and Maintenance
After the tailings storage facility is put into operation, Xinhai provides full-cycle value-added services, including capacity management, dam heightening, daily maintenance, safety assessments, and environmental remediation, ensuring the long-term safety, stability, and compliance of the facilities.
Leveraging sensors and automation instruments, Xinhai enables real-time transmission of key data to a centralized control system, providing 24/7 online monitoring and high-frequency, even continuous, data updates. Through real-time monitoring, potential risks can be identified early, avoiding the missed inspections and delays associated with traditional manual checks, significantly enhancing safety. The centralized platform allows operators to remotely monitor the status of multiple monitoring points, reducing the costs and time associated with on-site inspections. Automated data collection and processing minimize human errors, ensuring that the operation and maintenance of the tailings storage facility are more efficient, safe, and intelligent.
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Zimbabwe 500t/d Gold Mining and Concentrator + TSF Project
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Yantai TSF Project
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