Development of material and compaction

requirements for a mixed clay/sand tailings

impoundment liner
Michael A. Malusis, Ph.D., P.E.
Bucknell University, Lewisburg, PA

Melanie Davis, P.E.

MWH Americas, Fort Collins, CO

Daniel Overton, P.E.

Engineering Analytics, Fort Collins, CO

David Castelbaum, P.E.

Tetra Tech, Fort Collins, CO

Toby Wright, P.E.

Uranium One USA, Fort Collins, CO
 Introduction

 Proposed 30-acre uranium tailings

storage facility (TSF) in semi-arid area of
western U.S.

 Site depositional environment is

primarily Aeolian (surficial fine sand
deposits underlain by sandstone)

 Proposed multi-layer liner system for

TSF includes 300-mm-thick compacted
clay liner (CCL)

 CCL requirements:
• Fines content ≥ 30 percent
• Maximum particle size = 25.4 mm
• Minimum plasticity index = 10
• Field hydraulic conductivity (kF) ≤ 10-9 m/s
 Introduction (cont.)

 Clay borrow stockpile present on-site

(imported several years ago)

 On-site clay borrow volume is

insufficient for construction of CCL

 Results of prior testing in off-site clay

source area indicated that the borrow
clay may be highly plastic (USCS CH; PI
values between 30 and 85)

 Value engineering approach: create CCL

material consisting of mixed on-site clay
and on-site sand (USCS SM and SP-SM)
 Objectives of Study

 To characterize the on-site borrow clay and on-site borrow sand (grain size
distribution, Atterberg limits, mineralogy, etc.)

 To evaluate candidate clay/sand design mixtures

• Design goals for CCL mixture: PI < 30, USCS CL or SC

 To develop material and compaction specifications for a mixed clay/sand CCL that
provide a high degree of confidence in achieving kF ≤ 10-9 m/s
 Borrow Characterization
 Eight test pit samples collected from each borrow area (1 sample per 5,000 m 3).
 All samples tested for grain size distribution, Atterberg limits, and water content.
 Two samples tested for mineralogy (>70% montmorillonite and mixed illite/smectite).

Borrow Sand (USCS SM) Borrow Clay (USCS CH)

Fines content = 13.5 to 22.7% Fines content = 75 to 90%
Clay content = 31 to 44%
Plasticity Index = 36 to 49
 Candidate Design Mixtures
(CBC = Composite Borrow Clay; CBS = Composite Borrow Sand; Proportions by dry wt.)

1. 40% CBC/60% CBS

• USCS SC
• PI = 16
• Fines content = 44%

2. 50% CBC/50% CBS

• USCS CL
• PI = 18
• Fines Content = 51%

3. 60% CBC/40% CBS

• USCS CL
• PI = 24
• Fines Content = 61%
 Compaction Testing

 Compaction energies:
• Modified (MOD; ASTM D1557)
• Standard (STD; ASTM D698)
• Reduced (RED; 60% of STD energy)

 Results indicate:
• Trends are as expected
• Degree of saturation at optimum (Sopt) =
81.8 to 88.3% (avg Sopt ~ 85%)
• Line of optimums established as line of
constant saturation (S = 85%)
• Single line of optimums is adequate for all
mixtures

 Closed symbols represent specimens saved

for lab hydraulic conductivity (kL) testing
(flexible-wall; ASTM D5084)
 Lab Hydraulic Conductivity (kL)
 Average effective stress = 34.5 kPa (5.0 psi); Hydraulic gradient < 30 in all tests
 Mixture containing 40% CBC was eliminated from consideration (k L = 8.5x10-10 m/s)
 Results show decreasing trend in kL as w passes from dry side to wet side of optimum
 All wet-side test specimens with ≥ 50% CBC exhibit k L ≤ 2x10-10 m/s
 Relationship Between kL and kF
 What value of kL provides high confidence in achieving the required kF?

• 44 total data points

• 89% of data plot below kF/kL = 5

• Data suggest that kL ≤ 2x10-10 m/s

is reasonable design target for
achieving kF ≤ 10-9 m/s

Data from Benson et al. (1999) for CCLs

compacted primarily wet of line of optimums
Acceptable Compaction Zone (ACZ)

 CCL design mixture = 55  5% borrow clay

 Encompasses combinations of w and d for

which kL ≤ 2x10-10 m/s was demonstrated

 Minimum d for ACZ set at 15.3 kN/m3 (95%

relative compaction based on standard energy)

 Maximum w of 25% for workability

 Construction Issues

 Field mixing process must achieve intimate mixing of sand and clay

 Moisture conditioning and clay hydration also are critical for successful construction of CCL

 Robust field QA/QC is necessary to ensure adequate mixing and proper placement (within ACZ)

 Field hydraulic conductivity testing to verify kF ≤ 10-9 m/s

 Conclusions

 Mixed sand/clay CCL represents a “value engineering” approach

• Eliminates need for off-site clay borrow material
• Reduces desiccation potential of constructed CCL

 “Line of Optimums” approach is effective as a means to establish design requirements (material

and compaction specifications) for the mixed sand/clay CCL

 Acceptable compaction zone accommodates the potential for a five-fold increase in field
hydraulic conductivity relative to lab hydraulic conductivity

 Design provides high confidence that required field hydraulic conductivity will be achieved if the
material and compaction specifications are met

 Robust field QA/QC is recommended

QUESTIONS?