1. Introduction

1.1. Preamble

The production and safe storage of tailings is an integral waste management procedure of standard mining projects as well as some industrial and power plant operations. Tailings are fine-grained waste rocks that are conventionally discharged as slurries into long-term storage facilities (Vick, 1983Blight, 2010Kossoff et al., 2014Jefferies and Been, 2016). Given that tailings disposal is necessary insofar as operations continue, tailings dams are perpetually evolving structures that are raised in stages over the span of several years to decades, with some impoundments being among the largest man-made structures in the world (Vick, 1983ICOLD, 2001). When unfavourable conditions persist in a storage facility (i.e. when a large volume of tailings are very wet, contractive and/or overlain by ponded water), a triggering mechanism may initiate a dam breach resulting in a mass movement of failed materials into the downstream environment (Dobry and Alvarez, 1967Chandler and Tosatti, 1995Blight, 2010Morgenstern et al., 2015Morgenstern et al., 2016Robertson et al., 2019).

Voluminous tailings flows are capable of catastrophic, highly mobile behaviour, with some events rendering considerable infrastructural damage, geomorphological impact, environmental contamination and socio-economic cost (Troncoso et al., 1993Kossoff et al., 2014Takahashi, 2014Macías et al., 2015Bowker and Chambers, 2015Bowker and Chambers, 2017Cuervo et al., 2017de Lima et al., 2020). Some tailings flows have also led to mass casualties when travelling through inhabited areas, with a few examples including 1937 Los Cedros in Mexico (300+ deaths; Macías et al., 2015), 1965 El Cobre in Chile (200+ deaths; Dobry and Alvarez, 1967), 1985 Stava in Italy (268 deaths; Chandler and Tosatti, 1995Takahashi, 2014) and 2019 Feijão in Brazil (272 deaths; Robertson et al., 2019de Lima et al., 2020). The occurrence of three high-profile incidents (Mt. Polley in Canada and Fundão and Feijão in Brazil) over a span of just five years (2014–2019) has further raised concerns about large at-risk facilities (Morgenstern et al., 2015Morgenstern et al., 2016Bowker and Chambers, 2017Cuervo et al., 2017Morgenstern, 2018Robertson et al., 2019Santamarina et al., 2019de Lima et al., 2020ICMM et al., 2020Franks et al., 2021Chovan et al., 2021). Two recent examples of catastrophic tailings flows are presented in Fig. 1 (Petley, 2020aPetley, 2020b).

Fig. 1
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Fig. 1

A seemingly high frequency of such incidents has generated public scrutiny of the tailings management industry (Azam and Li, 2010Morgenstern, 2018Santamarina et al., 2019ICMM et al., 2020WISE, 2020Franks et al., 2021Chovan et al., 2021). These events continue to add to a growing list of tailings dam failures that includes over 350 reported incidents (ICOLD, 2001Azam and Li, 2010Lyu et al., 2019Ghahramani et al., 2020WISE, 2020). These failure cases also occur at a time of increasing mine waste production commensurate with declining ore grades and increasing demand for metals (ICOLD, 1996IIED, 2002Mudd, 2007Jones and Boger, 2012Mudd and Boger, 2013Adiansyah et al., 2015Owen et al., 2020), thus raising an urgent need to reduce the frequency and consequences of these incidents.

1.2. Scope and objectives

Geotechnical assessments have conventionally been carried out to retrospectively examine the root causes of catastrophic tailings dam failures, with particular focus on the stability of the embankment, tailings and foundation (e.g. Fourie et al., 2001Olalla and Cuellar, 2001Morgenstern et al., 2015Morgenstern et al., 2016Robertson et al., 2019). This work has contributed to the steady development in the conceptual understanding of mining geotechnics over time (Bishop, 1973Vick, 1983Blight, 2010Jefferies and Been, 2016). Comparatively less research attention has been directed towards the post-failure behaviour of tailings within the context of high-mobility mass movements (e.g. Takahashi, 1991Takahashi, 2014Macías et al., 2015Cuervo et al., 2017de Lima et al., 2020). Existing literature on tailings flows has mainly been limited to outflow-runout empirical assessments (e.g. Rico et al., 2008bLarrauri and Lall, 2018Ghahramani et al., 2020) with some case studies devoted to characterizing runout behaviour (e.g. Blight et al., 1981Takahashi, 1991Takahashi, 2014Macías et al., 2015de Lima et al., 2020). However, it remains to be holistically examined through a case history perspective how the field behaviour (i.e. post-breach outflow and runout behaviour) of tailings flows may be influenced by variable predisposing hydro-geotechnical conditions, trigger and breach mechanisms and downstream terrain properties.

To address this knowledge gap, this paper introduces a novel comprehensive database of 63 tailings flows (listed in Table 1) that ensued from failed tailings impoundments between 1928 and 2020. The database considers tailings and impoundment properties, predisposal and triggering variables, breach-outflow characteristics and downstream runout behaviour (contingent upon data availability). The development of this database was supported by an exhaustive review of source literature and a dense collection of processed satellite and aerial images of tailings flow case histories that were remotely analyzed through a geographic information systems (GIS) approach. In a supplementary article, we describe the case selection criteria, data procurement methods and sources, data uncertainty and remote sensing-GIS techniques. The database, supplementary article and imagery collection are published in an online open-source data repository hosted at Scholars Portal Dataverse (Rana et al., 2021).

Table 1. Chronologically sorted list of 63 selected tailings flows from 1928 to 2020. The database, supplementary article and imagery collection are published in an online open-source data repository hosted at Scholars Portal Dataverse (Rana et al., 2021). The case IDs are used as data point indicators in plots presented in Section 7.

ID Site/Event Country Year ID Site/Event Country Year
1 Barahona Chile 1928 33 Inez USA 2000
2 Los Cedros Mexico 1937 34 Sasa Macedonia 2003
3 Huogudu China 1962 35 Comurhex France 2004
4 Bellavista Chile 1965 36 Cavendish UK 2007
5 Cerro Negro Chile 1965 37 Mineracao Brazil 2007
6 El Cobre Chile 1965 38 Kingston USA 2008
7 La Patagua Chile 1965 39 Xiangfen China 2008
8 Los Maquis Chile 1965 40 Karamken Russia 2009
9 Sgorigrad Bulgaria 1966 41 Ajka Hungary 2010
10 Hokkaido Japan 1968 42 Caudalosa Peru 2010
11 Certej Romania 1971 43 Las Palmas Chile 2010
12 Cities Service USA 1971 44 Kayakari Japan 2011
13 Bafokeng South Africa 1974 45 Gullbridge Canada 2012
14 Deneen Mica USA 1974 46 Philex Philippines 2012
15 Arcturus Zimbabwe 1978 47 Talvivaara Finland 2012
16 Mochikoshi Japan 1978 48 Obed Mtn. Canada 2013
17 Church Rock USA 1979 49 Dan River USA 2014
18 Tyrone Mine USA 1980 50 Mt. Polley Canada 2014
19 Cerro Negro Chile 1985 51 Fundão Brazil 2015
20 Niujiaolong China 1985 52 Luoyang China 2016
21 Stava Italy 1985 53 Jharsuguda India 2017
22 Veta del Agua Chile 1985 54 Mishor Rotem Israel 2017
23 Ollinghouse USA 1985 55 Tonglvshan China 2017
24 Stancil USA 1989 56 Cadia Australia 2018
25 Merriespruit South Africa 1994 57 Cieneguita Mexico 2018
26 Tapo Canyon USA 1994 58 Cobriza Peru 2019
27 Omai Guyana 1995 59 Essar India 2019
28 Marcopper Philippines 1996 60 Feijão Brazil 2019
29 Pinto Valley USA 1997 61 Hindalco India 2019
30 Aznalcóllar Spain 1998 62 Luming China 2020
31 Aitik Sweden 2000 63 Singrauli India 2020
32 Baia Mare Romania 2000        

Using this wealth of information, this paper undertakes a timely global review of the complex conditions and processes involved in the initiation and field behaviour of tailings flows. This synthesis also presents some empirical observations while evaluating the limitations associated with broad, deterministic approaches to predicting site-specific post-breach behaviour. In this regard, we must note that the database is not intended to provide revised empirical correlations to be unconditionally applied in breach-runout analyses, but rather to provide assistance to practitioners performing site assessments identify case histories with characteristics and pre-failure conditions similar to the dam under consideration. Given the number of terminologies that are presented in this comprehensive work, Table 2 lists the definitions and descriptions of relevant variables in order to promote consistency and allay potential misinterpretation.

Table 2. A list of important terminologies presented in our collated research on tailings flows. This summary table is aimed to promote consistency and allay potential misinterpretation of key parameters. Further details on these variables are provided throughout the present paper and Rana et al. (2021).

Term (Notation) Definition/Description
Tailings Fine-grained, wet to saturated waste rocks that are conventionally impounded behind a dam. In the present work, we define “tailings” to include both tailings solids and interstitial (pore) water. Although predominantly a product of mining operations, we also consider fine-grained, wet to saturated impounded waste from industrial and power plant operations (e.g. bauxite and fly ash) to be classed as tailings in this work.
Supernatant pond Ponded free water overlying the tailings in the impoundment. The supernatant pond consists of process water used during mineral extraction and may also include naturally sourced free water such as rainfall and snowmelt.
Total impounded volume (VT) The total volume of tailings and supernatant pond that is impounded in the facility prior to a dam breach.
Total outflow volume (VF) The total volume of tailings and supernatant pond that flows through a dam breach into the downstream environment.
Total outflow ratio (VF/VT) The ratio of the total outflow volume to total impounded volume at a breached dam site, typically expressed as a percentage.
Mean dam breach width (Bw) The average horizontal width of the dam breach channel opening as estimated from GIS measurements on satellite imagery or as reported in literature for cases without available satellite imagery.
Zone 1 and Zone 2 The primary impact zone (Zone 1) is defined by the extent of the main solid tailings deposit, which is characterized by remotely visible or field-confirmed sedimentation, above mean bankfull elevations if extending into downstream river channels. The secondary impact zone (Zone 2) is defined as the area downstream of Zone 1 that is further impacted by the tailings flow in some form. Secondary impacts may include flood or displacement wave impacts (i.e. fluid impacts above typical downstream water levels) and sediment plume impacts (i.e. below typical downstream water levels). If no water bodies intercept the released tailings, then the entire runout is classified as Zone 1. The present work focuses on the Zone 1 impact of tailings flows. We refer the reader to Section 6.3Ghahramani et al. (2020) and Rana et al. (2021) for further details on Zone 1 and Zone 2.
CDA class A conceptual framework devised by the Canadian Dam Association (CDA) that categorizes breach-flow events into four classes (CDA, 2020): 1A (liquefied tailings with supernatant pond), 1B (non-liquefied tailings with supernatant pond), 2A (liquefied tailings without supernatant pond) and 2B (non-liquefied tailings without supernatant pond). The assignment of CDA classes is a subjective endeavour, particularly for complex breach events. The present work applies this framework primarily as a qualitative indicator variable to observe the influence of tailings liquefaction and supernatant pond on tailings flow behaviour.
Travel path confinement A qualitative attribute of the downstream terrain that indicates whether the travel path was channelized (i.e. laterally confined), terminally confined and/or unconfined. If a tailings flow runout was partially channelized and unconfined, we grouped the case according to the dominant mode of confinement.
Travel path substrate A qualitative attribute of the downstream environment that describes the travel path substrate based on GIS interpretation of satellite imagery. The present work applies this attribute primarily as an indicator variable to observe the effects of travelling on major river channels on tailings flow mobility.

2. Tailings storage facilities

Mining operations involve the development of a geological ore body to extract minerals while producing vast quantities of mine waste. The nature of this waste varies from dry, angular, very coarse (sandy gravel to boulder-sized) waste rocks stripped from the overburden to very wet, fine-grained (sandy to silty) tailings that comprise the residuum of the comminution process (Blight, 2010). Although predominantly produced from mining activities, tailings are also generated from some industrial and power plant operations (e.g. bauxite from alumina and fly ash from coal). These materials are also considered as tailings in this work, whereby we define “tailings” to include both tailings solids and interstitial (pore) water (Table 2). The types of tailings may be generally grouped as either hard rock (e.g. lead, zinc, copper, gold, silver, molybdenum, iron, nickel and uranium) or soft rock (e.g. coal, fly ash, phosphate and bauxite) depending on the specific gravity (Vick, 1983Small et al., 2017Ghahramani et al., 2020). The use of hard and soft rock tailings as a qualitative indicator variable (as in Section 7 of this paper) has previously been recommended as a simpler way to distinguish the type of ore due to the numerous distinct types of tailings and the data sparsity corresponding to each type (Small et al., 2017Ghahramani et al., 2020). As reflected in our database of tailings flows, the number of data points still remains very low for soft rock tailings (n = 6) compared to hard rock tailings (n = 33).

To protect against environmental contamination, tailings are conventionally impounded behind a compacted dam that is typically built out of the coarse (sandy) fraction of tailings, foundation materials and/or waste rockfill/earthfill (Blight, 2010Kossoff et al., 2014). Tailings are typically hydraulically discharged as a low-density slurry into the impoundment, with the finer materials (slimes) settling further into the central core while the coarser materials make up the beach abutting the dam. To prevent the generation of surface dusts and acid mine drainage through oxidation processes, the tailings slimes may form the base of a supernatant pond consisting of process water used during mineral extraction (Fig. 2Blight, 2010Kossoff et al., 2014). Tailings storage facilities may be constructed as partially enclosed impoundments on a slope, across a valley or as fully enclosed impoundments on relatively flat terrain. In keeping with the rising volume of the impounded material, tailings dams may be raised in the upstream direction (i.e. over the impounded tailings), in the downstream direction or vertically upwards using the centerline method (Fig. 2Vick, 1983ICOLD, 2001Blight, 2010). It is worth noting that the rate of tailings deposition, consolidation and dam construction varies considerably depending on the site, hence impoundment age does not necessarily correlate with the total impounded volume (and by extension total outflow volume and flow mobility), as reflected in our database of tailings flows. Nevertheless, over time, tailings dams may impound tens of M m3 of tailings, and in many cases supernatant ponds, over heights of tens of m, thus creating a long-term anthropogenic footprint on a previously natural landscape. Large impoundments thereby represent sources of significant potential energy capable of extreme downstream geomorphological, geochemical and socio-economic consequences in the event of catastrophic failure (Dobry and Alvarez, 1967Takahashi, 1991Kossoff et al., 2014Macías et al., 2015Cuervo et al., 2017de Lima et al., 2020).

Fig. 2
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Fig. 2

3. Susceptibility to mass flow behaviour

The practice of hydraulically disposing tailings into a large wet impoundment, without allowing for the necessary time for settlement and consolidation, may promote a loose, saturated tailings structure that is susceptible to brittle stress-strain behaviour and liquefaction following a triggering mechanism (Martin and McRoberts, 1999Blight, 2010Jefferies and Been, 2016). Numerous case studies (e.g. Dobry and Alvarez, 1967Fourie et al., 2001Morgenstern et al., 2016Robertson et al., 2019) indicate that a high propensity for tailings to liquefy en masse – whether induced statically or seismically – is typically congruent with high moisture contents approaching or exceeding the liquid limit (i.e. liquidity index >1.0) and positive state parameters indicating contractive properties. The state parameter (ψ) is the difference between the existing void ratio and the critical void ratio (i.e. the void ratio at which no volume change occurs during shear as determined from reconstituted samples) of the tailings at the same mean effective stress (Jefferies and Been, 2016). In saturated conditions, loose, contractive materials (+ψ) are potentially liquefiable upon undrained shearing whereas dilative materials (−ψ) are more compact and demonstrate greater resistance to liquefaction (Vick, 1983Martin and McRoberts, 1999Fourie et al., 2001Blight, 2010Morgenstern et al., 2016). During flow liquefaction, impounded tailings undergo rapid strain-softening (i.e. progressively lower shear stress is needed to induce the same level of strain) as the interstitial water begins to carry part of the load during material contraction until residual strength is attained. This initiates rapid flow-like movement of the liquefied mass as it escapes through the breach into the downstream environment (Morgenstern et al., 2016).

Several tailings flows have also initiated due to the uncontrolled or accidental release of a supernatant pond, irrespective of the liquefaction susceptibility of the impounded tailings. Cases such as 1937 Los Cedros and 2014 Mt. Polley have involved the prolonged, rapid discharge of free water with eroded non-liquefied tailings, displaying field behaviour akin to a sediment-rich outburst flood (Macías et al., 2015Morgenstern et al., 2015Cuervo et al., 2017). When combining the effects of flow liquefaction with the availability of a voluminous pond, the resulting outflow may be typified by additional fluidization, catastrophic discharge rates, multiple flow surges, larger outflow volumes and widespread downstream inundation (CDA, 2020). Still, the 2015 Fundão, 2016 Luoyang and 2019 Feijão runouts have demonstrated that the occurrence of liquefaction is a sufficient condition to initiate catastrophic mass flows, even without the influence of free water (Reid and Fourie, 2017Palu and Julien, 2019de Lima et al., 2020).

Given this knowledge, the Canadian Dam Association (CDA) introduced a classification matrix that attempts to categorize breach events into one of four distinct classes based on the involvement of free water within the outflow and the occurrence of tailings liquefaction (Fig. 3Small et al., 2017Martin et al., 2019CDA, 2020Gildeh et al., 2020). This sets a useful conceptual framework that may also be adopted as an indicator variable for tailings dam breach-runout prediction studies. The present work applies the CDA framework purely as a qualitative indicator variable to observe the influence of tailings liquefaction and supernatant pond on tailings flow behaviour. It should be noted, however, that the task of assigning CDA classes is prone to subjectivity particularly for complex cases where, for instance, (i) tailings liquefaction only occurred locally, (ii) the volume of free water was small enough to question the corresponding influence on runout behaviour, (iii) the failure occurred in multiple stages of different CDA classes or (iv) rather than a standard dam breach, the failure manifested due to a deficient drainage system that produced a prolonged single-stage discharge into the downstream terrain.

Fig. 3
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Fig. 3

4. Causative variables

When tailings impoundments are in a precarious state, the failure process may be accelerated by one or multiple predisposing factors, resulting in a marginally stable dam that fails catastrophically upon the onset of even minor triggering mechanisms (Morgenstern et al., 2015Morgenstern et al., 2016Robertson et al., 2019). Table 3 lists variables that may compromise tailings dam integrity with reference to corresponding adverse effects and failure modes. Whereas heavy rainfall, seismic liquefaction and foundation instability are common “external” trigger variables (Rico et al., 2008aAzam and Li, 2010Lyu et al., 2019), a metastable state may be preconditioned by “internal” anthropogenic root causes related to the engineering design, operations or regulations (Morgenstern, 2018). In particular, adequate drainage of interstitial and free water and sufficient compaction of the dam core are considered vital internal variables that may help mitigate the adverse effects of rain-induced overtopping, seismic/static liquefaction, internal erosion of the dam core and excessive groundwater seepage (Azam and Li, 2010Lyu et al., 2019Clarkson and Williams, 2021).

Table 3. Reported variables that may precondition or trigger tailings impoundment instability.

Variables Adverse Effects Case Examples References
Seismic activity
  • -

    Tailings liquefaction

  • -

    Acceleration of creep deformation

1928 Barahona; 1965 El Cobre; 2015 Fundão Dobry and Alvarez (1967)Troncoso et al. (1993)Morgenstern et al. (2016)
Intense precipitation
  • -

    Higher liquefaction susceptibility (loss of suction)

  • -

    Higher potential for pond overtopping

  • -

    Structural failure of drainage system

  • -

    Excessive seepage

1985 Stava; 1974 Bafokeng; 1994 Merriespruit Chandler and Tosatti (1995)Midgley (1979)Wagener (1997)
Embankment deficiency
  • -

    Loose dam core may cause internal erosion (piping) and seepage

  • -

    Oversteepened dam slope may trigger slope instability

1974 Bafokeng; 1995 Omai Midgley (1979)Vick (1996)
Groundwater seepage Excess pore pressure development and higher liquefaction susceptibility along base of impoundment 1966 Sgorigrad; 1985 Stava; 2019 Feijão Lucchi (2009)Chandler and Tosatti (1995)Robertson et al. (2019)
Static liquefaction
  • -

    May increase shear stresses against dam to the point of catastrophic collapse

  • -

    May occur in response to sudden loss of confinement (static unloading)

2015 Fundão; 2019 Feijão Morgenstern et al. (2016)Robertson et al. (2019)
Foundation instability Sudden undrained brittle failure of dam foundation triggering dam breach 1998 Aznalcóllar; 2014 Mt. Polley; 2018 Cadia Alonso and Gens (2006a)Morgenstern et al. (2015)Jefferies et al. (2019)
Internal creep deformation Undrained failure when peak strength of tailings is exceeded 2008 Kingston; 2019 Feijão AECOM (2009)Robertson et al. (2019)
Tailings properties
  • -

    Strong bonding of stiff tailings may lead to higher peak strength and higher susceptibility to sudden brittle failure

  • -

    Abundance of clay minerals may induce geochemical reactions and higher thixotropy

  • -

    High-pH pore and free water may cause caustic corrosion of dam core

2009 Karamken; 2010 Ajka; 2015 Fundão; 2019 Feijão Mecsi (2013)Morgenstern et al. (2016)Bánvölgyi (2018)Glotov et al. (2018)Robertson et al. (2019)
Anthropogenic factors
  • -

    Rapid tailings deposition may inhibit tailings consolidation

  • -

    Mine blasting vibrations may accelerate creep deformation

  • -

    Vandalism may cause structural issues

  • -

    Engineering, operations and regulator mismanagement (e.g. inappropriate dam construction, inadequate drainage system and sub-standard monitoring)

1965 El Cobre New Dam; 2009 Karamken; 2015 Fundão Dobry and Alvarez (1967)Glotov et al. (2018)Morgenstern et al. (2016)Morgenstern (2018)

A significant percentage of failed tailings dams have been those that were raised in the upstream direction (Lyu et al., 2019Franks et al., 2021), including 36 of the 43 tailings flow cases with reported dam raising methods in our database. The upstream design has thus received scrutiny, including a prohibition in Chile since 1970 after a series of earthquake-triggered failures (Dobry and Alvarez, 1967Villavicencio et al., 2014Valenzuela, 2016Troncoso et al., 2017). Failures of some upstream-raised dams have been attributed to partial founding on soft, compressible, poorly consolidated slimes that consequently underwent lateral extrusion, undrained creep and development of excess pore water pressures to the point of failure (Dobry and Alvarez, 1967Troncoso et al., 1993AECOM, 2009Morgenstern et al., 2016). However, as counter-argued by Vick (1992)Martin and McRoberts (1999) and Morgenstern (2018), the prominent causes of these instabilities may lie in improper design, construction and operation of the facility – including, but not limited to, the overabundance of contractive materials, insufficient drainage and seepage control and a loose embankment core – rather than the general upstream method itself.

Fig. 4 presents a temporal bar chart distribution of major causative variables for 46 tailings impoundment failures that produced mass flows. We note that assigning causative variables to complex case histories can be a subjective task. For example, as summarized in our database, some failures (Bafokeng, Arcturus, Stava, Karamken, Ajka and Fundão) resulted from a complex interplay of multiple causative variables (e.g. Table 3). In addition, Fig. 4 excludes deep-rooted, mainly anthropogenic predisposal variables related to engineering, operational or regulatory issues (Morgenstern, 2018). The causative variables in Fig. 4 are grouped as follows:

  • “Weather hazards” include heavy rainfall, snowfall, storms and freeze-thaw cycles. These factors may lead to a number of failure mechanisms such as overtopping, internal erosion (piping), seepage, excess pore pressures and structural drainage issues.

  • “Embankment deficiency” highlights structural issues of the tailings dam core (i.e. lack of compaction, use of improper construction materials and/or oversteepened slopes) that may promote internal erosion, piping, excess seepage and/or slope instability.

  • “Seismic activity” refers to earthquake-induced liquefaction failures or seismic tremors that accelerate the impoundment towards failure.

  • “Unstable foundation” refers to impoundment foundations that were hydrogeologically, geotechnically and/or topographically unsuitable to sustain high, rapid vertical loading.

  • “Structural drainage deficiency” refers to deficiencies within the interstitial and supernatant pond drainage system, resulting in static liquefaction, overtopping or structural failure.

 

Fig. 4
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Fig. 4

Weather hazards have contributed to 39% of the 46 cases, followed by seismic activity (26%), structural drainage deficiency (24%), embankment deficiency (20%) and unstable foundation (15%). Tailings flows triggered by weather hazards have steadily increased in frequency over time, which is consistent with the findings of Rico et al. (2008a)Azam and Li (2010) and Lyu et al. (2019) in relation to tailings dam failures in general. The meteorological effect on tailings dam stability may be manifested in several ways. For instance, heavy rainfall may trigger erosional failures of embankments through pond overtopping (Midgley, 1979Wagener, 1997). Long-term increases in regional rainfall may trigger loss of suction in unsaturated zones of impounded tailings and lead to undrained conditions (Robertson et al., 2019). Freeze-thaw cycling may cause structural drainage deficiency and loosening of the embankment core, while spring-time melting of snow and ice covers on the impoundment may reduce the freeboard between the dam crest and impounded materials and exacerbate undrained conditions (Chandler and Tosatti, 1995UNEP and OCHA, 2000). Extensive ice formation contributed to the recent catastrophic failure of the decant drainage system at the Luming tailings facility in China (Fig. 1A; Petley, 2020a).

The stability of geological foundations underneath large impoundments has become of critical concern following the 1998 Aznalcóllar, 2014 Mt. Polley and 2018 Cadia incidents – all of which occurred with minimal advance warning (Gens and Alonso, 2006Morgenstern et al., 2015Jefferies et al., 2019). Such experiences have underscored the importance of identifying the weakest units in the foundation for consideration in tailings impoundment design. Moreover, the setting of large impoundments on mountain or valley slopes may yield significant changes to the local hydrogeologic regime, while inducing a perpetual state of high gravitational driving stresses against the embankment. The disasters of 1966 Sgorigrad, 1985 Stava and 2019 Feijão were all preconditioned in part by consistent groundwater seepage into the sloping foundations (Chandler and Tosatti, 1995Lucchi, 2009Robertson et al., 2019). Undetected groundwater upwelling was also a key contributory variable in the 1994 Tapo Canyon and 2010 Las Palmas dam breaches (Harder Jr. and Stewart, 1996Villavicencio et al., 2014).

Tailings flows triggered by seismic activity have steadily reduced in frequency over time. A majority of early seismic liquefaction failure cases were in Chile and Japan (Torres and Brito, 1966Dobry and Alvarez, 1967Okusa et al., 1980Ishihara, 1984); since then, both nations have advanced the state of operational practice such that tailings facilities have withstood powerful earthquakes (Yasuda et al., 2013Villavicencio et al., 2014Ishihara et al., 2015Valenzuela, 2016Troncoso et al., 2017). A novel concern, however, is the potential role of sequential seismic tremors in accelerating the failure of marginally stable facilities (Agurto-Detzel et al., 2016Morgenstern et al., 2016).

5. Magnitude–frequency distribution

The documented total outflow volumes (VF) in our database range from 20,000 m3 to 32 M m3, summing to a cumulative total of 136 M m3. Based on our review of pre-existing datasets of tailings dam breaches and tailings flows (e.g. ICOLD, 2001Rico et al., 2008bBowker and Chambers, 2015Small et al., 2017Larrauri and Lall, 2018Ghahramani et al., 2020WISE, 2020), we conclude that all tailings flows with VF ≥ 200,000 m3 over the period 1965–2020 (totalling to 34 cases) have been publicly documented and are thus included in our database. Fig. 5A illustrates the temporal cumulative VF distribution of the 34 tailings flows that fall within this “complete interval”. An estimated 40% of the cumulative VF (~50 M m3) occurred in the 49-year period between 1965 and 2013, whereas the remainder (60% or ~ 75 M m3) occurred since 2014. This recent spike is dominated by the combined VF of ~67 M m3 from the 2014 Mt. Polley, 2015 Fundão and 2019 Feijão incidents.

Fig. 5
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Fig. 5

A cumulative magnitude-frequency distribution of the complete interval of 34 cases is shown in Fig. 5B. A rollover effect is observed whereby the slope of the power-law relation [Log F = −0.88 (log VF) + 4.93] flattens below a VF threshold of ~1 M m3. This statistical rollover phenomenon has also characterized natural debris flows and is attributed to either data bias (undersampling) at smaller volumes or the manifestation of limiting physical conditions under which mass flows occur (Guthrie and Evans, 2004Hungr et al., 2008). Using the power-law formula, we calculate that tailings dam breaches that have produced catastrophic mass flows with VF ≥ 1 M m3 have occurred at a mean recurrence interval of 2–3 years over the period 1965–2020. For context and comparison, we also draw in Fig. 5B a minimum-estimate magnitude-frequency curve of the 5-year planned volumes of 1260 tailings impoundments constructed globally over the period 1965–2019. This data is derived from a detailed but incomplete record in Franks et al. (2021) that was collated through voluntary survey responses from extractive companies. By extrapolation of the curve, it is estimated that a tailings facility with a planned 5-year storage volume of ≥200 M m3 was constructed at least once every year over the period 1965–2019. The magnitude-frequency curves of tailings flows and constructed tailings impoundments are noted to be similar in shape and form.

6. Initiation and field behaviour

6.1. Breach development

An impending breach of a marginally stable tailings dam may be preceded by a prolonged period of small-scale deformations, cracking and/or seepage (Shakesby and Whitlow, 1991Mecsi, 2013Morgenstern et al., 2016Jefferies et al., 2019Rotta et al., 2020Grebby et al., 2021). A catastrophic breach may be accompanied by a series of explosion-like noises and shockwaves signifying the detachment and collapse of large portions of the dam core (Torres and Brito, 1966Blight and Fourie, 2005Macías et al., 2015de Lima et al., 2020). Global instability (i.e. near-complete failure of a dam) may occur rapidly in 10–20 s when triggered by liquefaction in upstream-raised, partially enclosed impoundments sitting on sloping terrain (typically ≥4°) (Dobry and Alvarez, 1967Okusa et al., 1980Colombo and Colleselli, 2003Robertson et al., 2019de Lima et al., 2020). In some cases, a vulnerable section of the dam may detach rapidly, slide some distance and progressively disintegrate in response to increased driving stresses from liquefied tailings (Torres and Brito, 1966Alonso and Gens, 2006bJefferies et al., 2019). When the failure mode is overtopping and/or internal erosion of a ring-dyke facility, the breach may progressively develop over several hours prior to the catastrophic surge (Blight et al., 1981Shakesby and Whitlow, 1991Wagener, 1997). In such events, a fully formed breach channel typically attains the shape of an inverted trapezoid, achieving maximum width at the crest. In our database, we report the mean breach widths (defined in Table 2) as provided in case literature when applicable (e.g. Blight et al., 1981) or from our independent GIS measurements on available satellite imagery.

6.2. Outflow process

The post-breach outflow behaviour of impounded materials is highly complex and depends on the failure mechanism and site conditions (Martin et al., 2015CDA, 2020). Some insight into outflow processes can be gained from performing a case review that is categorized into CDA classes (Fig. 3). As remarked earlier in Section 3, the effort of assigning CDA classes to breach events is prone to subjectivity depending on the application objective and case complexity. In this work, we apply the CDA framework purely as a qualitative indicator variable to observe the influence of tailings liquefaction and supernatant pond on tailings flow behaviour.

6.2.1. 1A cases (flow of liquefied tailings with a supernatant pond)

During 1A erosional breach cases, the mass flow may be preceded by a steady outflow of excess free water which may serve as a premonitory sign of impending failure (Midgley, 1979Blight et al., 1981Wagener, 1997Blight and Fourie, 2005). In the 1994 Merriespruit case, where the total outflow volume was ~630,000 m3, residents reported observing a strong flow of water passing through the village for ~2 h prior to the catastrophic surge (Wagener, 1997). A significant proportion of the 70,000–100,000 m3 of free water from the facility (30,000–50,000 m3 of rainwater and 40,000–50,000 m3 of supernatant pond) was incorporated within this initial steady flow (Wagener, 1997). The subsequent rapid surge consisted of statically liquefied tailings and residual free water. In the case of 1974 Bafokeng, following ~1.5 h of water seeping along the dam face, ~3 M m3 of statically liquefied tailings (18% of Dam 1) were mobilized over 40–60 min with a mean velocity and discharge of ~10 m/s and ~ 1000 m3/s, respectively, through the ~110 m wide breach (Blight et al., 1981).

During rapid 1A breach events, the total outflow ratios and peak discharges may vary widely depending on site conditions and failure modes. As a consequence of the 1965 Chilean earthquake, 45% of the El Cobre Old Dam (1.9 M m3) escaped the facility whereas almost 100% of the freshly deposited, poorly consolidated tailings in the adjacent New Dam were mobilized (0.5 M m3), resulting in a combined outflow of 2.4 M m3. Eyewitnesses reported “waves of liquid columns” (interpreted as sand blows) on the New Dam tailings surface as a consequence of rapid pore pressure relief (Torres and Brito, 1966Dobry and Alvarez, 1967). The 1985 Stava outflow, predisposed by inadequate drainage and the sloping foundation (12°–16°), achieved a catastrophic peak discharge of 28,160 m3/s, indicating that it took just 13 s for 63% of the Upper and Lower Basins (~180,000 m3) to be released (Takahashi, 1991Takahashi, 2014). During the outflow sequence in such catastrophic 1A breaches, liquefaction flowsliding may continue for hours as a series of slope failures that regress backwards until stronger scarp materials are encountered, typically rendering steep, semi-circular scarps surrounding sub-horizontal (1° to 5°) wet terraces (Dobry and Alvarez, 1967Shakesby and Whitlow, 1991Blight and Fourie, 2005Blight, 2010Robertson et al., 2019CDA, 2020).

A contrasting example was the 2009 Karamken incident (Russia) that was caused by heavy rainfall and lack of maintenance of the decommissioned facility (Glotov et al., 2018). Approximately 1.1 Mm3 of floodwaters and 0.3 Mm3 of liquefied tailings and dam materials outflowed through the ~50 m wide breach at a relatively low peak discharge of ~10 m3/s for ~30 min before reducing to ~1.4 m3/s over the subsequent three days (Glotov et al., 2018).

6.2.2. 1B cases (flow of non-liquefied tailings with a supernatant pond)

In catastrophic 1B cases, the mass flow may occur in one or multiple surges lasting for several hours to a few days depending on free water availability (i.e. volume and distribution of the pond and, if applicable, the intensity and duration of rainfall). For example, the 1937 Los Cedros flow involved at least three major flow surges over a span of 48 h with a total outflow volume of ~1.5 M m3 (Macías et al., 2015). The flow pulses were triggered and sustained by a torrential rainstorm that lasted several days and provided a sufficient supply of free water to induce progressive softening and erosion of the impounded tailings. The peak discharge through the breach was retrospectively modelled to be ~8000 m3/s with a solids concentration of ~50% (Macías et al., 2015).

The Mt. Polley event also involved at least three flow surges (Morgenstern et al., 2015Cuervo et al., 2017). The peak discharge through the ~160 m wide breach was calculated to be 5130 m3/s – about a thousand times higher than the probable maximum 200-year flood for Hazeltine Creek (Cuervo et al., 2017). Of the total outflow volume of 24.4 M m3 (a third of the impoundment), 30% (7.3 M m3) consisted of tailings solids, 27% (6.5 M m3) was interstitial water and 43% (10.6 M m3) comprised the supernatant pond (Morgenstern et al., 2015Cuervo et al., 2017). Helicopter videos of the impoundment captured 8 h after failure showed active sheet erosion of tailings, dendritic drainage channels and cirque-like arcuate headscarps (Fig. 6Morgenstern et al., 2015). As the steep scarps kept migrating headward due to fluvial erosion, the height drop in the headscarp enhanced pond drainage from farther ends of the facility, which in turn further promoted headscarp retreat akin to a geomorphic cascade sequence. In a natural landscape, this process may take hundreds to thousands of years whereas the pond supply was exhausted within a few hours following the Mt. Polley breach (Morgenstern et al., 2015).

Fig. 6
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Fig. 6

Occasionally in 1B cases, dam failure may occur not due to a breach but instead as a result of a deficient drainage system, triggering a prolonged single-stage discharge into the downstream environment. An example is the 1995 Omai case that was caused by blockage and damage of drainpipes that in turn induced internal erosion of the improperly constructed dam core (Vick, 1996). The resulting cyanide-laden leakage lasted for almost five days, with the initial peak discharge to the adjacent Omai River estimated to be ~50 m3/s (Vick, 1996).

6.2.3. 2A cases (flow of liquefied tailings without a supernatant pond)

The 2015 Fundão and 2019 Feijão events (Morgenstern et al., 2016Palu and Julien, 2019Robertson et al., 2019de Lima et al., 2020) are archetypes of catastrophic 2A cases. The outflow behaviours of 2A cases depend on the proportional volume of liquefiable tailings, which was atypically high in both the Fundão and Feijão cases despite the absence (or negligible volume) of impounded free water. Both sets of tailings contained high iron contents, corresponding to strong inter-particle bonding between oxidized grains which in turn elevated stiffness and specific gravity. Global instability of both facilities subsequently occurred as a sudden brittle response to the high peak strength being exceeded (Morgenstern et al., 2016Robertson et al., 2019). The Fundão Dam collapse released 32 Mm3 of liquefied tailings (61% of the impoundment), whereas 75% (9.7 M m3) of the Feijão tailings underwent flow failure. Palu and Julien (2019) report an initial volumetric solids concentration of 57.5% in the Fundão outflow, while the peak discharge remains unknown. The Feijão outflow occurred as a singular surge with a peak height of 30 m that was completed in less than 5 mins (Robertson et al., 2019). Despite the decommissioned state of the Feijão facility, the contractive tailings were very wet owing to excess groundwater seepage and intense antecedent rainfall, leading to an interstitial water concentration of ~50% (Robertson et al., 2019). Fig. 7 shows a post-failure view of the Feijão impoundment.

Fig. 7
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Fig. 7

6.2.4. 2B cases (flow of non-liquefied tailings without a supernatant pond)

2B events are relatively under-reported in available literature. In 2B cases, the tailings are typically characterized by higher solids concentrations with a lower susceptibility to flow liquefaction. Failures of these tailings may be mobilized as slope failures or slumps with relatively limited downstream impact (Small et al., 2017Martin et al., 2019CDA, 2020).

6.3. Runout behaviour

Large volumes of failed tailings are capable of exhibiting highly mobile, destructive behaviour in the downstream environment. In addition to the properties of the flowing mass (i.e. contractive tendency and volumetric proportions of free water, pore water and solids), the downstream topography also exerts a strong control over the runout behaviour. A case review is presented below that provides insight into the observed effects of topographic confinement, slope and substrate on the velocity, geomorphic impact and mobility of tailings flows.

Following the approach of Ghahramani et al. (2020), we note that our case review focuses on the primary impact zone (“Zone 1” extent) of tailings flows, which is defined by the extent of the main solid tailings deposit characterized by remotely visible or field-confirmed sedimentation, and above mean bankfull elevations if extending into downstream river channels (Table 2 and Fig. 8). The secondary impact zone (Zone 2) is defined as the area downstream of Zone 1 that is further impacted by the tailings flow in some form. Secondary impacts may include flood or displacement wave impacts (i.e. fluid impacts above typical downstream water levels) and sediment plume impacts (i.e. below typical downstream water levels). If no water bodies intercept the released tailings, then the entire runout is classified as Zone 1. Our focus on Zone 1 is therefore due to the geomorphological and potential human consequences associated with the primary impact zones of tailings flows. This approach is consistent with how analogous mass movements have historically been mapped and characterized, while providing value from a life loss risk management perspective. Moreover, as indicated by Ghahramani et al. (2020), Zone 2 extents are typically more challenging to evaluate due to the variability of downstream flow mixing conditions, the relatively transient nature of secondary impacts and the inherent limitations of the adopted GIS-remote sensing methods (e.g. image resolution). Our GIS-calculated values of Zone 1 runout distances, inundation areas and travel path angles (as reported in our database) are also inevitably subject to uncertainties associated with satellite image resolution constraints and measurement subjectivity, further details of which are provided by Rana et al. (2021).

Fig. 8
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Fig. 8

6.3.1. Channelized runouts

Extremely rapid flow velocities (>5 m/s; Cruden and Varnes, 1996Hungr et al., 2001Hungr et al., 2014) and high kinetic energy have typically been exhibited by voluminous tailings flows meandering along relatively narrow creek or stream channels and/or relatively steep bed slopes. The seismically triggered Barahona flow in 1928 is among the first documented cases. The flow achieved a maximum superelevation of almost 60 m along laterally incised bends (indicating peak velocity of ~30 m/s) when flowing down the narrow Barahona creek channel with a bed slope of 4°–7° (Troncoso et al., 1993Troncoso et al., 2017). The surge resulted in the deaths of 54 people and the destruction of a bridge, railway station and campsite (Troncoso et al., 1993Troncoso et al., 2017). Nine years later, at least 300 people were killed during the Los Cedros disaster (Macías et al., 2015). The flow sustained velocities of over 20 m/s (peak of ~25 m/s) and depths of over 5 m (peak of ~20 m) for ~2 km (Macías et al., 2015). The extremely rapid field behaviour was attributed to the location of the tailings facility that rested on a natural incline of ~22° in mountainous terrain, resulting in high gravitational driving stresses. Moreover, the mass flow travelled along the Tlalpujahua stream channel that had been further wettened by the triggering torrential rainstorm. Evidence of high mechanical energy included significant volumes of entrained debris including trees, roof tiles and detached building blocks (Macías et al., 2015).

The catastrophic field behaviour of the Stava flow (268 deaths) is well-documented (Takahashi, 1991Takahashi, 2014Chandler and Tosatti, 1995Colombo and Colleselli, 2003Luino and De Graff, 2012). The initial flowslide travelled 600 m and crashed into the left bank of the Stava valley at a velocity of 8.3 m/s, destroying 31 buildings in the process (Chandler and Tosatti, 1995). The flowslide then accelerated along Stava Creek (bed slope of 2°–12°), sustaining a mean velocity of 25 m/s (peak of 31 m/s) until Tesero village 3.3 km downstream of the breach (Chandler and Tosatti, 1995Takahashi, 1991Takahashi, 2014). The flow depth progressively decreased from an initial high of 20 m to 5 m near Tesero (Takahashi, 1991Takahashi, 2014). Almost 50,000 m3 of debris – including soils, trees, and buildings – were entrained from both sides and the bottom of the Stava Creek valley which indicates an entrainment ratio of 0.28 (Hungr and Evans, 2004Luino and De Graff, 2012). The flow entered the Rio Avisio 4.2 km downstream and subsequently dammed the river and formed a 500 m long lake upstream (Luino and De Graff, 2012).

A high erosional capacity was also demonstrated by the Mt. Polley flow along Hazeltine Creek valley (Cuervo et al., 2017). Although the tailings were not liquefied, a high volumetric proportion of free and interstitial water (70% or 17 M m3) enabled a 9 km long runout over a travel path angle of 1.3°. The mass would have travelled much further had it not been terminally confined by Quesnel Lake. Multiple knickpoint features up to 10 m in height were observed along the valley (Cuervo et al., 2017). Up to 0.6 M m3 of creek sediments and vegetation were eroded and transported during the flow – almost equal to the entire outflow volume following the Merriespruit Dam breach. Steeper channel gradients along the creek corresponded to higher velocities and kinetic energy, which in turn exacerbated erosion (scouring depths of up to 7 m) while limiting deposition (less than 0.1 Mm3) (Cuervo et al., 2017).

Catastrophic tailings flows may be capable of overwhelming creek channel banks to render widespread floodplain damage. An example is the seismically triggered El Cobre flow that killed over 200 people in 1965 (Fig. 9Torres and Brito, 1966Dobry and Alvarez, 1967). A peak velocity of ~13 m/s was estimated from arrival times and run-up heights (Torres and Brito, 1966). The tailings travelled along the El Cobre creek channel but carried sufficient energy and discharge to overwhelm both banks along the 11 km long runout, achieving a maximum width of 1 km. Similarly, the failure of the Plakalnitsa Dam (caused by intense groundwater seepage and rainfall) just a year later triggered a 6 km long runout along a creek channel through the village of Sgorigrad (Bulgaria). The tailings overwhelmed both banks and caused the destruction of 156 homes and the deaths of 107–488 people (Lucchi, 2009Mossa and James, 2013).