Digital Twins: A Gamechanger for TSF Design & Management

The mining industry is entering a new era. An era where real-time data, simulation, and automation are transforming how tailings storage facilities (TSFs) are designed, monitored, and managed.

At the center of this transformation is a powerful tool: the Digital Twin. A digital twin is a virtual replica of a physical TSF, continuously updated with real operational data. It allows engineers, operators, and decision-makers to “see the facility before touching it,” test scenarios safely, and predict behaviour long before issues arise.

As mining operations across Africa and beyond begin to embrace digital transformation, digital twins are quickly becoming a cornerstone of modern tailings management.

1. What Exactly Is a Digital Twin?

A digital twin is more than a 3D model. It is a living, data-driven system that mirrors the real facility by integrating:

• Instrumentation data (piezometers, inclinometers, flow meters)

• Drone and satellite imagery

• Geotechnical models

• Climate and hydrological inputs

• Material properties, deposition rates, and operational data

This creates a real-time view of a TSF’s performance, past, present, and predicted.

2. Why Digital Twins Matter for TSF Engineering

Tailings dams are complex, dynamic structures affected by water movement, changing loads, climate variability, and deposition patterns. Conventional review methods often detect issues late.

Digital twins, however, enable:

1. Early Detection of Instability

By combining sensor data with predictive models, digital twins highlight abnormal behaviour long before it becomes critical.

2. Real-Time Monitoring

Operators can visualize pore pressures, deformation, and seepage paths as they change.

3. Better Risk Management

Multiple “what-if” scenarios can be simulated, such as extreme rainfall, rapid loading, or equipment change.

4. Improved Decision-Making

Engineers can test mitigation measures digitally before applying them in the field.

5. Enhanced Regulatory Compliance

Digital twins support transparent reporting and alignment with standards like GISTM.

3. How Digital Twins Strengthen TSF Design

Digital twins are not only operational tools, they also enhance design and planning by:

• Optimizing drainage and water balance

• Testing embankment geometries

• Predicting long-term settlement

• Improving material selection and compaction strategies

• Guiding phased construction

This reduces uncertainty and improves long-term stability.

4. A Boost to Transparency and ESG Performance

As investors and communities demand clearer visibility into mine operations, digital twins provide:

• Visual summaries for stakeholders

• Accurate safety reports

• Clear evidence of monitoring and maintenance

• Improved trust and accountability

Transparency becomes easier, and risk communication becomes stronger.

5. The AES Approach

At African Engineering Services (AES), we integrate digital modelling with advanced geotechnical engineering to deliver TSF solutions that are smarter, safer, and future-ready. Our approach includes:

• Instrumentation planning and integration

• Real-time monitoring systems

• 3D geotechnical modelling

• Predictive stability and seepage simulations

• Continuous digital updates throughout the TSF lifecycle

Together, these tools help mines operate more confidently and proactively in line with international best practices.