Digital integration boosts safety, productivity, sustainability at Anglo American Barro Alto mine
A project to digitise geotechnical data for risk management at an Anglo American nickel mine in Brazil represents a ‘paradigm shift’ and sets new standards for innovation in the mining sector, according to Seequent, The Bentley Subsurface Company.
Anglo American, in Brazil, operates nickel and iron ore assets, with a Nickel Unit in Barro Alto in the northern part of Goiás state.
At Barro Alto, the lack of sufficient geotechnical information, absence of integrated models to support decision making, limited the risk-management capabilities in the mine, Seequent says.
To address these concerns, Anglo’s Corporate Geotechnical Department embarked on a project to digitise its geotechnical risk-management processes and rid the operation of the traditional manual methods and disconnected software and databases, which were error-prone and unreliable.
Corporate Geotechnics Team Engineering Geologist, Felipe Vilela, says Seequent’s Leapfrog Geo was selected to integrate all available data and to create dynamic 3D geoscience models, and Seequent Central and Bentley Systems ProjectWise, both project management systems, were also chosen to ensure all stakeholders had seamless access to version-controlled models and documents.
“Anglo needed an integrated technology solution to combine geochemical, geological-structural, geophysics and geotechnical data into a dynamic 3D model bringing agility, reliability and collaboration to their workflow, and minimising risk of geotechnical failures that could damage the environment and jeopardise lives,” Vilela says.
‘Paradigm shift’ for Anglo
By promoting safer and more efficient mining operations, and reducing operational and environmental risks, the project has directly contributed to the integrity of mine structures and workforce safety while enhancing productivity through more reliable and updated datasets, Vilela says.
“In a sector where technical workflows are often overlooked and geotechnical data under-valued, this initiative represents a significant paradigm shift,” he says.
“Proper use of geotechnical information is essential for effective risk management, and the implementation of standardised workflows with continuous improvement and formal validation remains rare in mining. This project demonstrated that innovation, technical control, and efficient management can co-exist in an integrated system, with direct impact on safety and decision making.
“It was necessary to re-invent the way of working, unifying software platforms and leveraging existing data that had never been used for geotechnical purposes.”
Seequent Segment Director, Mining, Dr Janina Elliott, says just because things have always been done in a certain way doesn’t mean there isn’t an opportunity to set new standards.
“In fact, there has never been a better time. Geoscience technology is evolving rapidly,” Elliott says. “By actively supporting interconnected workflows, real-time 3D visualisation, and cloud-enabled project management, teams are enabled to holistically evaluate data faster.
“For the first time, geotechnical engineers are freed up to act on insights and innovate proactively rather than creating reactive measures.”
Innovative approach
Before the project, modelling at the mines was largely manual, fragmented and prone to inconsistencies, which limited the effectiveness of risk management and reduced the reliability of geological interpretations.
“Leapfrog Geo was crucial in enabling more accurate visualisation of units and features,” Vilela says, “as well as facilitating real-time analysis of field data. Implicit modelling significantly reduced the time required to generate and update models, optimising the daily workflow of technical teams.
“Seequent Central played a key role in the collaborative sharing and updating of short- and long-term models, making version control auditable and traceable.”
It also enabled continuous validation and reconciliation workflows based on reliable field data.
Bentley Systems’ ProjectWise was adopted as the official platform for document management across departments, centralising geotechnical pit projects, mine plans validation and modelling documentation.
“This centralisation mitigated risks of rework and inconsistency by ensuring that all teams operated with updated and official information,” Vilela says.
Significant leaps forward
Better integrated and digitised data has boosted the understanding of the Barro Alto operation, according to Seequent. The workflow enhanced predictability of the mine’s behaviour from a geotechnical perspective as well as its operational safety, efficiency and collaboration.
“The project also delivered positive financial impacts and can be easily replicated at other company sites, establishing itself as a model for technical excellence and risk management,” Vilela says.
Other key achievements from using the products include faster model updates, improvements to business sustainability and alignment with the company’s core values.
There has been a 75% reduction in the time required to update 3D geomechanical models, according to Seequent, which were previously revised only once a year and can now be updated quarterly, or as new relevant data becomes available.
Vilela explains: “Improved knowledge, risk management and predictability allowed the release of areas previously constrained by geotechnical uncertainties, reducing the size of geotechnical exclusion zones. The project has made it possible to target previously uncertain areas, significantly increasing the projected recovery in the medium-to long-term, estimated at 120-140%.”
There has also been a reduction in environmental risks associated with slope failures that could exceed licensed pit boundaries, according to Vilela, with the methodology helping better understand and control environmentally-restricted areas, such as zones beyond the environmental licence boundary. Defining geotechnical limits also reinforced the preservation of environmental protection areas by avoiding unplanned advancements or interventions outside geotechnical safety parameters.
“From a social and operational standpoint, the digitisation of the process and the consolidation of data in integrated platforms contributed to a more controlled operation, with a reduced risk of accidents that could affect people or equipment,” he added.
Anglo American’s approach to digitising geotechnical risk management at Barro Alto earned recognition as one of three finalists in the 2025 Going Digital Awards in Infrastructure – Subsurface Modelling and Analysis category.
The post Digital integration boosts safety, productivity, sustainability at Anglo American Barro Alto mine appeared first on International Mining.