FOUNDATIONS FOR THE FUTURE: QAL’S DEVELOPMENT OF FOUNDATIONS

FOR ITS FUTURE RESIDUE DISPOSAL AREA

Richter P1*, Massey A2 and Callum J2
1
QAL Queensland Alumina Limited, Gladstone, QLD, Australia
2
GHD Consulting Engineers, Brisbane, QLD, Australia
Abstract
Queensland Alumina Ltd (QAL) has developed and updated its Long Term Residue Disposal Strategy to address the challenge
of providing additional red mud storage capacity beyond 2008 and remain on the existing footprint. Reviews of previous
studies confirmed and updated early recommendations that a dedicated Neutralisation Facility be established along with
a change from downstream to upstream raising of the dam embankments to satisfy long term storage requirements to
2046.
The design and construction of foundations within an existing residue disposal facility poses its own individual challenges.
High groundwater levels, designing to protect and minimise impacts on habitat, liquefiable sands, un-neutralised residue,
unknown foundation conditions and excavating 3 metres below sea level were all part of the considerations necessary
in developing and constructing the future foundations for QAL’s upgraded residue disposal area. This paper describes
the design issues that were addressed in developing the strategy and the challenges of constructing the first stage.
Adequate foundation investigation and time for design development are keystones to success in conversion of brown
field construction sites. Conditions can still change even with the most extensive investigation and consideration. The
observational approach is being applied as a viable fall back position when the unexpected occurs.
In October 2007 QAL successfully completed the foundations for the first stage of the upgraded residue storage area.

1. Background and Site Description

Queensland Alumina Ltd (QAL) is presently one of the world’s
larger alumina refineries and is located in Gladstone, Queensland,
Australia. The refinery is jointly owned with holdings apportioned
to RioTinto (80%) and Rusal (20%). QAL commenced operations
in 1967 and has been progressively expanded to its current
alumina refining capacity of around 3.9 million tonnes per year.
Red mud (bauxite residue) is a by-product from the process to
refine alumina from bauxite. Approximately 0.8 tonnes of red
mud (dry) per 1.0 tonne of alumina is produced in this process
with over 3 million tonnes produced in 2007. This production rate
is expected to increase with incremental alumina production,
bauxite grade changes and major refinery expansion projects.
QAL currently manages the red mud by neutralising the final
washer underflow with seawater and directing the resultant low-
density slurry via some seven kilometres of overland pipelines into
dedicated residue containment areas, Red Mud Dams 1 and 2
(RMD1 and RMD2) on Boyne Island. This method has historically
been a very effective and low-cost approach however the area is
close to capacity and additional storage volume is now required.
To date additional capacity was provided by downstream raising
of the perimeter embankments. This method is no longer viable
due to the large volumes of earthfill required and insufficient
downstream space. Figure 1 details the general arrangement of
the refinery and residue facility.
The residue containment area is situated on Boyne Island and
is in the order of 1000 hectares in size. The site consists of two
containment areas (RMD 1 and 2) and is bounded by South Trees
Inlet and estuarine mudflats along the North, West and South,
with Gladstone Harbour to the North and beaches to the East.
The area is framed on the west by a ridge about 3km long varying
in height from 30 to 55 metres above sea level. An eastern ridge
of similar height and length forms a visual barrier and isolates
the residue area from the local Boyne Island community.
Power
BSL Smelter and
water
services
RMD#1 - 421ha
N
RMD#2 -575ha
7km
QAL
South Trees inlet
Figure 1. Location of Refinery and Residue Facility RMD 1 and 2.
The aluminium smelter of Boyne Smelters Limited (BSL) is
separated from the QAL residue areas by Spillway Creek with the
pot lines some 200 metres distant at the closest point.
High voltage overhead power transmission lines, and raw and
potable water pipelines cross the residue storage areas between
RMD1 and 2 and along the southern perimeter of RMD2.
2. Sensitive Areas
As a result of strategy investigations it has been established that
the site is bounded by or contains a number of environmentally
and culturally sensitive areas. These include:
• A section of South Trees Inlet north of the site is heritage
listed marine parks zone
• Vegetation along a 2km east verge of RMD1 is considered
to be the state and federally protected vine thicket habitat of
the Black Breasted Button Quail
• Vegetation along a 2km verge between RMD2 and the
local community is considered to be the state and federally
protected habitat of the Brigalow Scaley Foot Legless Lizard
• A number of culturally significant protected sites along the
west side of the disposal area bounding with South Trees
Inlet.

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 3. Long Term Residue Disposal Strategy
QAL has developed its long term residue disposal strategy and
has set a nominal capacity horizon of the year 2046. With the
assistance of GHD a review of previous studies and updated
design was undertaken. This work confirmed and updated
recommendations that a dedicated Neutralisation Facility be
established at the red mud storage facility. It also confirmed that
a change be made from downstream to upstream raising of the
embankments of both dams to satisfy storage requirements for
the longer term, maximise utilisation of the Boyne Island site and
overcome the current limitations on further embankment lifts.

‘Upstream construction’ requires future containment

embankments to be built over deposited red mud which must
gain adequate strength to meet geotechnical stability criteria.
To achieve increased strength, it is essential that the red
mud deposition process allows adequate time for drying and
Figure 3. Comparison between a) Upstream and b) Downstream Raising
consolidation. Submergence of the red mud by decant water Methods
must be avoided. The large added volumes of seawater required
to achieve red mud neutralisation must be managed to minimise In adopting upstream raising, QAL are preparing new operating
flooding of the red mud drying areas. methods and procedures to include:

The agreed Residue Disposal Strategy includes the construction
of a Neutralisation Facility to firstly neutralise and then secondly
clarify and separate a large proportion of the water fraction from
the neutralised red mud underflow. This allows for much of
the neutralisation waters to be handled separately and drying
requirements for upstream construction to be achieved. The
strategy will provide residue storage capacity for a cumulative
alumina production of some 250 million tonnes.
The strategy will be implemented in a number of stages over its life.
Alumina and red mud production rates and volumes determine
the timing of these stages. Capital and operating expenditure
will be scheduled to meet storage requirements. The most
significant step for the project is Stage 1. This is the initial stage
when the processing facility and the permanent foundations and
initial embankments for the conversion of RMD1 are designed,
constructed and commissioned. A general arrangement of the
future red mud containment concept is shown in Figure 2.
Part C
Reactivate
Neutralising
RMD1
Facility
Part D
RMD 2
subdivided into
Parts A & B
Part E
Maintain Decant
Existing
Decant
• Operation of a multipoint perimeter discharge system
• Monitoring and control of red mud strength improvement
• Control of red mud beach development
• Water management monitoring and controls
• Monitoring and control of groundwater levels
• Regular review of filling schedules and long range planning
of raises.
5. Stage 1 Residue Disposal Project
The initial Stage 1 of the Residue Disposal Project comprises:
• Re-establishment of red mud storage in Parts D and E, the
first new areas on RMD1
• The construction of new starter embankments for the
upstream construction in RMD1
• The construction of foundations and civil works necessary
for future raises in RMD1
• The establishment of a new on site neutralising facility to
neutralise and thicken the mud prior to placement
• Red mud delivery and distribution pipework to RMD1 and
decant water management systems.
6. Design Challenges and Solutions
Designing the conversion of an existing single stage residue
N storage area into a multi-stage, upstream raised structure
required developing solutions to issues not often encountered in
tailings storage facilities. These were not always related to design
and included gaining the understanding and confidence of the
owner and regulators in unfamiliar concepts.

6.1 Ground Conditions

Figure 2. Proposed Future Red Mud Containment Arrangement
4. Adopting Upstream Construction
The main differences between upstream raising and conventional
downstream raising are compared in Figure 3. For downstream
raising the construction is not affected to any great extent
by the operator performance. In the upstream raise system,
the deposited tailings form part of the retaining structure and
therefore the operator performance and placement of the red
mud become a more critical factor. If the tailings do not achieve
a target density and strength, or if water levels become too high,
then the construction becomes more difficult and the integrity
and safety of the storage could be compromised. Therefore
whereas upstream raising can be a cost effective method of
storing red mud it requires significant system changes from the
traditional downstream, single point discharge storages.
The new red mud storage is located on the existing Red Mud
Dam 1 originally constructed over a wide coastal valley on Boyne
Island. It is bounded on the west and south by low hills and to the
east by sand dunes and swamps of Spillway Creek. Foundation
conditions below the existing red mud are variable and comprise
weak estuarine clays, alluvium, or low density sand dunes
underlain by weathered bedrock. The existing red mud is up to
11m deep and un-trafficable to most construction equipment.
Groundwater levels are close to the surface and the whole area
was prone to flooding.
An area of sand dunes to the north east side of Stage 1 Part
D supported a vegetation habitat that had to be protected. This
meant that groundwater levels could not be changed by any
significant amount during or after construction.

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 6.2 Stability
Geotechnical stability of embankments considers the likelihood
and consequence of structural collapse resulting in breech and
loss of the retained water or tailings. For the proposed upstream
raise solution the key drivers for stability at QAL were:
• The need to construct the new embankments over existing
low strength red mud underlain by weak foundation soils
• The recognition that the red mud and some of the sandy
foundation soils were susceptible to liquefaction
• An uncertain strength that could be mobilised in the future
neutralised red mud, and
• Tight controls on acceptable surface and groundwater
levels in the storage facility and downstream areas to meet
environmental requirements.
To gain an appreciation of the size of the project, Figure 4 shows
a typical section through the future storage facility at closure.
This shows that a large proportion of the existing red mud dam
and foundation soils provide support for the outer slopes of the
facility and that the future red mud will constitute most of the
retaining shoulders to the facility.
Figure 4. Typical Cross Section of the Completed Upstream Raised RMD1
The impact of low strength and liquefiable foundation soils was
addressed by the inclusion of a deep shear key of engineered fill
constructed below the initial embankment lift. Stability analyses
indicated that groundwater levels within the future red mud
would have to be maintained below specified levels and a system
of internal sub soil drains is proposed to be installed in stages as
the facility is raised. An observational approach to groundwater
pore pressures will determine if additional internal subsoil
drainage should be installed if piezometer monitoring indicates
unacceptable groundwater levels.
6.3 Safety in Design
Although practised by reputable design engineers and
constructors for many years it is now incumbent that design
solutions take account of safety in construction as well as
providing a safe end product. The major construction safety
concerns peculiar to the red mud dams were:
• Safe access over existing red mud and the potential for
bogging or engulfment
• Excavation through the red mud
• Stability of deep excavations in weak materials often with a
high groundwater table
• The presence of an operating red mud dam and decant
pond adjacent to the works area
• High voltage transmission lines and medium pressure water
supply pipelines crossing the site.
The design of the foundation key had to satisfy most of these
concerns.
Whereas initial investigations and theory indicated that the key
could be constructed, there was uncertainty with respect to the
stability of temporary slopes since this depended on assumed
variables such as method of construction and groundwater levels
at the time. Trial excavations and embankments were proposed
and constructed to provide:
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• Performance and empirical data to confirm the design
assumptions
• Contractor experience with working in these unique
conditions
• Confidence that the work could be achieved safely
• Specification requirements for safe work method statements
monitoring and change management as the excavations
proceeded.
A typical view of one of the trial excavations is shown in Figure 5.
Figure 5. Trial Excavation in Red Mud >8m Deep
The findings were included in the final design and specifications.
For example, indicative temporary batter slopes and materials
were specified that allowed construction below the water table in
both dewatered and flooded conditions.
6.4 Stage 1 Design
The first stage of the new storage facility was designed to maximise
the existing red mud footprint and to provide a consistent level
and geometry that would be a starter for ease of layout of future
raises.
A typical cross section through the initial Stage 1 raise is
presented in Figure 6. This shows that a large proportion of the
construction works comprised the excavation and backfilling of
the foundation key. The volume of below surface work was in the
order of 100,000 m3. The foundation for the starter embankment
is designed for the ultimate structure and represents a significant
investment in the first stage of construction.
Figure 6. Typical Cross Section of Stage 1 Raise and Foundation Key
6.5 Environmental Impact
Designing the red mud dam conversion to remain within the
existing lease area minimised changes to existing licence
conditions and generally simplified the application for change
process. However, some land clearing was necessary within
the lease and fauna and flora studies were carried out. These
identified several endangered habitats, including the rare Black
Breasted Button Quail in remnant vine thicket within the proposed
footprint. The dam embankment was realigned to preserve this
habitat.
7. Risk Analysis
A risk analysis process was used throughout the design
development of the strategy and Stage 1 design. Between the
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 GHD designers, third party reviewers, Owners, EPA representatives
and QAL the following risk evaluations were performed:

• FMECA Risk Assessment – covering the red mud dams

• Business Risk Assessment. Global overview.

The risk analysis process was a fundamental tool in assisting

operators, designers, stakeholders and Owners to appreciate the
scope and challenges to be overcome as a result of implementing
the strategy. In one instance the process was used to assist
in the decision making between two competing concepts of
embankment construction and red mud disposal.

Involvement of third party reviewers and also regulator experts

into the risk analysis provided a common understanding of the
project by all parties and gave an opportunity for groups to have
input before the process was complete.
8. Construction Challenges and Solutions
8.1 Safety
Construction over existing residue tailings requires close attention
to the health and safety of the work force and operations.
Construction through existing residue tailings to depths up to
about 11m required the development of safe working methods
in advance which could be modified as the excavation proceeded
and as experience was gained with the ground conditions.
A significant challenge was managing this process while
minimising risk and the impact of change on contract cost and
the environment (Figure 7).
Figure 8. 70t Truck Hauling along Central Road
8.3 The Observational Approach
The concept of the ‘observational approach’ was introduced by
Peck (1969) and is a well established method in earthworks
engineering that allows design assumptions to be verified and
refined during construction and operation. It is particularly useful
where conservative assumptions have had to be adopted and
there are opportunities to refine the design with improved data,
and where there is a need to improve or control ground conditions
that impact on the integrity of the structure. Opportunities for
QAL at the red mud dam include:
• Fine tuning of foundation excavations in response to as
found conditions
• Management of groundwater levels and uplift pressures
that could impact on slope stability
• Confirmation of strength of foundations, especially where
embankments have to be raised in stages to allow an
increase in strength to be developed
• Management of achieved red mud density and strength that
impacts on storage capacity, scheduling and stability, and
• Monitoring of red mud drying cycles that impact on operation
schedules and budgets.

Following the successful application of this process during

construction, long term monitoring systems are being established
to provide feedback for possible future improvements to operation
planning and the design of future raises.

Some examples of the observational method applied during

construction are described below.
Figure 7. Two Stage Excavation and Advancing Backfilling

8.2 Work Methods

The Contractor was required to provide work methods and
management plans for excavation of the foundation key,
spreading red mud spoil, constructing fills and managing surface
water. These were prepared after in depth briefings from the
designers. Trial excavations were included in the contract to allow
the Contractor to test and modify the construction method.

One challenge was the choice of earthmoving equipment

and its suitability to soft ground conditions. Ideally small, low
ground pressure plant is used in these conditions to minimise
settlement and the risk of bogging, however their productivity
is limited. Large capacity and heavy dump trucks were selected
by the Contractor in order to move the large volumes of cut and
Figure 9. Construction of the Foundation Key
fill within the project schedule. This resulted in work methods
that had to account for traffic loads as much as ground stability
Construction Control
(Figures 7 and 8).
In addition to normal earthworks quality control measures, the
project included specific requirements for excavation of the
foundation key. The key was designed to extend below the base
of the red mud and any loose sand and gravel deposits. The level
of this boundary was variable and was approximated from site
investigation data. Fine tuning of the key depth and confirmation

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 that it was embedded in the correct strata was provided in two
stages by:

1. Infill probing using cone penetrometers and boreholes at

50m centres along each side of the key invert, and
2. Visual observation and foundation mapping and sign
off by the designer plus as-built survey recorded by the
contractor.

In this way the costs of over excavation were minimised, design

criteria were confirmed, and a continuous record of foundation
conditions has been developed as reference material for the
future operation and maintenance of the red mud dam. Example
photographs of the key construction are shown in Figure 9.

Habitat Groundwater Management

The protected vine thicket habitat is located next to some of the

deepest foundation key excavations and is considered sensitive
to large groundwater level changes. Detailed hydrogeological
modelling indicated close connection between the aquifer below
the habitat and the key excavation area. A detailed monitoring
network was established including 15-minute interval data
loggers on two sites. This provided daily feedback to construction
managers. Water management within the excavations could then
be modified to maintain groundwater impacts within acceptable
bounds using both drainage sumps and recharge points.

9. Conclusions
This paper has described some of the challenges and issues
that had to be addressed when establishing a new upstream
constructed residue disposal area over an existing residue
storage area.

An innovative approach to addressing difficult and uncertain

conditions was developed to provide the Refinery owners with
confidence and understanding that the most effective solution
was adopted. This included establishing a review panel of
independent technical experts at an early stage in the project,
as well as staging investigations and design development, field
trials, workshops and risk assessments.

The potential to produce an over conservative and unnecessary

costly design due to uncertainties associated with predicting the
performance of critical elements was minimised by adopting
flexible designs with contingency measures that could be installed
at a later date. A construction and operating observational
approach philosophy has been adopted monitoring critical
elements such as red mud strength and groundwater levels. The
observations will be compared with design requirements and
trigger levels over the life of the structure and used to determine
if and when modifications are required.

The success of the foundation construction benefited from an

unseasonably dry rainy season in 2006/7. Recommendations
for similar projects elsewhere include making full allowance
for seasonal impacts in the construction timetable as well as
adopting a team or alliance approach; with owner, designers and
constructors working together to address the challenges. The
benefit of a constructive owner-constructer relationship at QAL’s
Stage 1 RMD1 project led to a successful outcome.

Acknowledgements
The authors wish to acknowledge Queensland Alumina Ltd and
GHD Pty Ltd for their support and approval to present this paper.

References
Peck, R B, 1969, ‘Advantages and limitations of the observational method in applied soil mechanics’, Geotechnique, vol. 19, no.2, pp. 171-187.

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