Methodology for the Prevention of Critical Failures in Iron Ore Stockpiles: A Case Study

Throughout the iron ore production chain, the material undergoes several transfers, making stockpiling essential for reserve formation, process support, or product homogenization. However, due to the artificial geometry of stockpiles slope, there is an inherent risk of structural failure, which may cause significant damage to nearby facilities, equipment, and personnel. Considering the scarcity of methodologies focused on minimizing the risk of failures in iron ore stockyards, this study proposes a preventive approach aimed at reducing critical events. A multidisciplinary team was assembled to identify, evaluate, and analyze the main risk factors associated with stockpile stability. Based on the data collected, a methodology was developed to guide operational procedures and improve risk management in stockyards. A case study was conducted focusing on iron ore stockpiles in Brazil, a country with a strong mining tradition. After implementing the proposed methodology, significant improvements were observed, including the elimination of critical stockpile failures. These results confirm the methodology’s effectiveness and highlight its potential to enhance safety, operational reliability, and risk control in mining stockyard operations.