Program Overview
Birdon partnered with Glencore to deliver one of the largest tailings relocation projects ever undertaken in Australia, relocating up to 25+ million m³ of tailings to unlock access to high-value coal seams.
The five-year program operates 24/7, using a dual dredge system moving tailings at rates of 625 litres per second, while maintaining high environmental performance and safety standards. This pioneering project demonstrates how dredging engineering, mine planning and water stewardship can work in concert to deliver economic, environmental and operational outcomes.
Quick Facts
- Client
Glencore – Bulga Open Cut Mine
- Location
New South Wales, Australia
- Lifecycle Stage
Operate
- Duration
5+ years
- Scope
25+ million m³ tailings relocated
- Production Rate
625 L/s (per dredge) continuous operation
- Key Outcome
10-year mine life extension
Objectives
- Relocate up to 25+ million m³ of tailings obstructing access to valuable coal seams
- Enable the recovery of high-grade resources and extend the mine’s operating life by 10 years
- Deliver a safe, continuous and environmentally compliant tailings transfer operation
- Minimise operational disruption to existing mining activities
Challenges
- Engineering around water availability as a limiting resource
- Continuous 24/7 operations requiring high mechanical reliability and workforce endurance
- Maintaining compliance with environmental and ESG performance requirements
- Managing site access in a changing terrain as dredging progresses
- Recruiting and retaining FIFO-ready operators within a competitive labour market
Birdon’s Approach
Birdon and Glencore’s collaborative engineering model ensured that dredging, civil and environmental design considerations were aligned from day one. The partnership exemplified how hydraulic readiness, civil infrastructure and operational culture are key enablers of success.
Outcomes & Impact
As of Q2, 2026 20 million m³ of tailings have been relocated, progressing toward the full 30 million m³ target. The project has enabled a 10-year extension of mine life, unlocking access to previously unreachable coal seams.
Operations have achieved zero environmental incidents, maintaining full compliance with water and waste regulations, with safety KPIs consistently achieved and sustained. The program has demonstrated a replicable and scalable dredging model for the Australian mining sector.
Testimonial
“Birdon has been a stand out partner in relation to their experience in dredging operations. There are some key individuals in Birdon that have been part of dredging for the majority of their career and their experience and guidance into how the dredging operations proceed here at Birdon is instrumental to the success of this project.”
Andrew Green
Tailings Production Superintendent
Capabilities in Action
- Hydraulic engineering with dredging systems sized to available water supply to optimise production and energy efficiency
- Integration of dual dredge systems supported by slurry and decant recovery systems with real-time telemetry and process control
- Environmental stewardship with zero exceedances and alignment to Glencore’s ESG commitments and water recycling benchmarks
- Operational planning including civil works for crane positioning, haul roads and pontoon and gangway infrastructure
- Workforce and operational alignment through 24/7 roster design supporting safety, fatigue management and retention
- Delivery under Birdon’s ISO-certified HSEQ Management System (ISO 9001, ISO 14001, ISO 45001)
