← Back to InsightsMining project controls

Mine Delivery Roadmap

How a large mining project, greenfields or brownfields, moves from business need to a delivered business case. Five views cover the phases and gates, how objectives become packages of work, how engineering matures, and how it turns into an estimate fit for each gate.

Select a phase to see its activities, deliverables and exit gate. Switch between greenfields and brownfields, and between open pit and underground, to change the content throughout. Gate names, maturity levels and examples are typical of industry practice; align them to your own stage-gate framework.

Lifecycle roadmap

Eight phases from business need to business case delivery. Each phase ends at a gate where the owner decides to proceed, recycle or stop. Select a phase to see what happens in it.

Define

Front-end loading (studies)

Execute

Operate

Phase

Stage

Opportunity

FEL 1 / Scoping

FEL 2 / PFS

FEL 3 / FS

EPCM delivery

Handover

Operations

Estimate class

No class

Class 5

Class 4

Class 3

Class 2, then Class 1

Final cost report

Operating budget

Post-investment review

Accuracy range

Benchmark only

-20 to -50% / +30 to +100%

-15 to -30% / +20 to +50%

-10 to -20% / +10 to +30%

-5 to -15% / +5 to +20%

Actuals

Engineering defined

n/a

0 to 2%

1 to 15%

10 to 40%

30 to 100%

100%

n/a

Schedule level

Milestones

Level 1

Level 2

Level 3

Level 4 and 5

By system

Ramp-up curve

Life-of-mine plan

Resource status

Exploration results

Inferred and Indicated

Probable Reserve declarable

Proved and Probable

Grade control model

Reconciliation starts

Mine-to-mill reconciliation

Annual reserve update

Exit gate

G0Opportunity framed

G1Concept selected for PFS

G2Preferred option selected

G3Final investment decision

G4Ready for commissioning

G5Handover to Operations

G6Nameplate demonstrated

G7Business case confirmed

Phase 04 of 08 . FEL 3 / FS . Greenfields

Feasibility

Define the selected option fully so the board can make the final investment decision.

Key activities

Basic engineering: P&IDs, GAs, 3D model to about 30%
Equipment specifications, RFQs and vendor budget quotes
MEL, EEL, instrument index and line list
HAZOP on P&IDs, constructability reviews
Execution plan, contracting and procurement strategy
Environmental authorisation, water use licence and mining right applications
Quantitative cost and schedule risk analysis

Key deliverables

Approved design criteria and specifications
P&IDs issued for design
GA drawings and 3D model
Priced MEL and EEL
Drawing register (MDR)
Class 3 estimate and basis of estimate
Level 3 schedule and basis of schedule
Project execution plan
Feasibility study report

Mining scope Open pit

Detailed pit design and life-of-mine schedule
Waste dump, stockpile and haul road design
Pit dewatering design
Mining contract or fleet purchase strategy

Project controls

Semi-detailed estimate from MTOs and vendor quotes
Integrated Level 3 schedule with agreed critical path
Cost and schedule QRA, P50 and P80 contingency
Control budget structure and earned value set-up

Exit gate

G3 Final investment decision

Is the defined project fundable and executable within the approved cost, schedule and risk?

Deliverables at Class 3 maturity
Contingency set at the board's chosen P-level
Critical permits granted or on a clear path
Funding secured, execution team ready

Estimate: Class 3
Accuracy: -10 to -20% / +10 to +30%
Defined: 10 to 40%
Schedule: Level 3

Accuracy ranges show the low and high bounds of the AACE range for that class; the actual range depends on technology, complexity and data quality. Mining studies are often quoted more simply: scoping about +/-35 to 50%, PFS about +/-25%, FS about +/-10 to 15%.

From business need to packages of work

The business need sets objectives. Objectives define the scope. The scope is broken into a work breakdown structure, then split into functional and contract packages that people can engineer, buy, build and control.

Step 1

Business need

Why the company needs this mine.

Replace production from a depleting operation and grow output, using a new hard-rock deposit with a 15-year reserve.Example only. The statement links to corporate strategy and names the value the project must create.

Step 2

Project objectives

Measurable targets the project is judged against at every gate. Figures are examples.

Safety

Zero fatalities, injury frequency below the group target

Production

5 Mtpa ROM ore at 92% plant availability

Recovery and product

Recovery and product grade as proven by testwork

Value

Positive NPV at the hurdle rate, IRR above hurdle, payback under 5 years

Capital and schedule

Capex within the FID budget at P80, first ore on the agreed date

Licence to operate

Permits on time, community commitments met

Life of mine

15 years or more from declared reserves

Step 3

Scope of work

What must be delivered to meet the objectives, and where it stops.

Scope statement

What will be built and delivered, in one page, traced to the objectives

Battery limits

Where the project starts and ends: grid connection point, water offtake, product despatch

Scope book

Scope by WBS area with capacities, design basis and key equipment

Interfaces

Owner, utilities, rail or port, third parties, existing operations

Assumptions and exclusions

What is in, what is out, and what the estimate assumes

Step 4

Work breakdown structure

The scope by physical area. The same codes carry through engineering, the estimate, the schedule and cost control. Only area 1000 changes between open pit and underground.

1000

Mining Open pit

Pre-strip and mine establishment
Mining fleet (owner) or contractor mobilisation
Haul roads and waste dumps
Pit dewatering
Explosives magazine
Mining workshops and fuel

2000

Process plant

ROM pad or bin and primary crushing
Conveyors and coarse ore stockpile
Milling and classification
Separation
Thickening, filtration and product handling
Reagents and plant services

3000

Tailings and water

Tailings storage facility
Return water and process water
Raw water supply
Water treatment

4000

Site infrastructure

Bulk earthworks and terraces
Site roads and drainage
Buildings: offices, workshops, stores, change houses, laboratory
Fuel, fire and security

5000

Off-site infrastructure

Power line and main substation
Raw water pipeline
Access road
Rail siding or port interface

6000

Indirects

EPCM services
Temporary facilities and construction camp
Freight, first fills, capital spares
Vendor representatives and commissioning

7000

Owner's costs

Owner's team
Permits and community
Operational readiness and pre-production
Insurance

8000

Contingency and escalation

Contingency from risk analysis
Escalation to the expenditure dates

Step 5

Packages

Each WBS area is delivered by functional teams and let as contract packages.

Engineering

Design criteria, calculations, specifications, equipment selection, MEL and EEL, reviews

Design and drafting

PFDs, P&IDs, layouts, GAs, 3D model, isometrics, single line diagrams, drawing register

Procurement

RFQs, bid evaluation, orders, expediting, inspection, logistics

Construction

Contractor management, site establishment, safety, quality, completions

Project controls

Estimating, planning and scheduling, cost control, risk, change, earned value, reporting

Commissioning

System definition, procedures, pre-commissioning through to handover

Owner's team

Governance, permits, community, operational readiness, funding

Typical contract packages (all mines)

EPCM (or EPC lump sum)
Early works and site establishment
Bulk earthworks and terraces
Civils and concrete
SMPP: structural, mechanical, platework, piping
Electrical and instrumentation
Buildings
Tailings storage facility
Power line and substation
Raw water pipeline
Long-lead equipment (mills, crushers, transformers), free-issued

Mining packages Open pit

Contract mining or owner fleet supply
Pre-strip
Explosives supply and blasting

Traceability: objective to package

Every objective should trace to the scope that delivers it and the package that carries it. Figures are examples.

Objective	Scope driver	WBS	Package
5 Mtpa ROM ore	Primary crusher about 850 t/h at 67% utilisation; mills sized to the same rate	2000	Long-lead equipment, SMPP
Recovery as per testwork	Separation circuit sized from testwork residence times and grind size	2000	Long-lead equipment, SMPP
Payback under 5 years	Capex ceiling drives trade-offs such as contract mining and modular plant	All	EPCM, project controls
First ore on date	Long-lead mills and transformers ordered at FID through early works	2000, 5000	Long-lead equipment
Permits on time	TSF design to the applicable standard, water use licence application	3000, 7000	TSF, owner's team
15 years or more	Pit stages and pushbacks sized to the reserve; fleet sized to the mining schedule	1000	Contract mining or owner fleet

How engineering is developed

Engineering starts from design criteria and ends in approved packs that estimators, buyers and builders can use. The same sequence runs in every study phase; what changes is how far each deliverable is taken.

Generic hard-rock flowsheet

Highlighted steps change with the mine type (Open pit). The plant and infrastructure behind them are common to both. The bottom line of each step is the main selection driver.

Open pit

Drill, blast, load

Drills, hydraulic shovels or excavators

Pit slope angle against strip ratio

Haulage

Trucks to the ROM pad

Rigid-frame haul trucks, or in-pit crusher and conveyor

Truck and shovel against in-pit crushing

ROM pad

Blending and tipping

ROM pad, rock breaker, tipping bays

Pad size against blending need

Primary crushing

Size ROM to conveyable

Gyratory or jaw crusher, apron feeder

Gyratory above about 1,000 t/h, jaw below

Conveying and stockpile

Buffer between mine and mill

Overland conveyors, coarse ore stockpile, reclaim feeders

Live capacity against surge need

Secondary and tertiary

Optional size reduction

Cone crushers, HPGR, screens

SAG circuit against crush and HPGR

Grinding

Liberate the valuable mineral

SAG and ball mills, cyclones

Grind size against recovery and power

Separation

Recover the valuable mineral

Flotation, leach or CIL, DMS, gravity, magnetic

Set by commodity and testwork

Dewatering and product

Make saleable product

Thickeners, filters, product storage and despatch

Moisture limit and transport mode

Tailings and water:Tailings thickenertoTailings storage facilitytoReturn water to plant

Commodity	Typical separation route
Base metals and PGMs	Flotation to concentrate, smelter interface
Gold	Gravity plus leach (CIL or CIP), elution, electrowinning, gold room
Iron ore and manganese	DMS, jigs, magnetic separation
Diamonds	DMS and X-ray recovery, no fine grinding
Lithium	DMS and flotation
Coal	DMS cyclones, spirals, flotation of fines

Engineering development sequence

Step 01
Basis of design and design criteria
Fix what the plant must do and the conditions it works in.
OutputsDesign basis, process design criteria, site data, codes and standards
Step 02
Testwork and process modelling
Prove the ore responds as assumed and model the circuit.
OutputsTestwork reports, mass and water balance, comminution and recovery models
Step 03
Trade-off studies
Compare the options that change cost, risk or value.
OutputsTrade-off reports and a recorded decision for each
Step 04
Process flow diagrams
Draw the circuit with stream flows and size the major equipment.
OutputsPFDs with stream tables, equipment sizing calculations
Step 05
Equipment selection
Specify, enquire, evaluate and select each major item.
OutputsDatasheets, RFQs, technical bid evaluations, vendor data
Step 06
Equipment and engineering lists
List every item the plant needs and its key data.
OutputsMEL, EEL and load list, instrument index, line list, valve list, cable schedule
Step 07
Specifications and drawing register
Write how things must be built and list every drawing to be produced.
OutputsGeneral and particular specifications, master drawing register (MDR)
Step 08
Drafting and 3D modelling
Turn the design into drawings and an integrated model.
OutputsP&IDs, plot plan, GAs, 3D model, isometrics, single line diagrams, civil and structural drawings
Step 09
Reviews
Check the design is safe, buildable, operable and maintainable.
OutputsInter-discipline checks, HAZID and HAZOP, 30/60/90% model reviews, constructability and value engineering
Step 10
Approval and release
Approve each document to the status the phase needs and release packs.
OutputsEngineering packs to estimating, procurement and construction

4 to 9Steps 4 to 9 iterate. Vendor data, review findings and HAZOP actions send drawings and lists back for revision before they are approved.

Trade-off studies typically run

All mines

SAG milling against HPGR or crush and ball mill
Grid power against self-generation or hybrid renewables
Conventional, thickened or filtered (dry-stack) tailings
Plant location: near the mine or near water and rail
Owner-operated against contractor-operated services

Mining Open pit

Truck and shovel against in-pit crushing and conveying
Owner fleet against contract mining
Steeper pit slopes against geotechnical risk
Autonomous haulage or conventional

Document status ladder

Each document climbs these steps. A gate sets the minimum status needed: IFD for most FS documents, AFC before construction.

IFRIssued for review

IFAIssued for approval

IFDIssued for design

IFTIssued for tender

AFCApproved for construction

As-builtRecord of what was built

Drafting set

Deliverable	What it shows	When it is issued	Lead discipline
Block-flow and PFDs	Circuit, major equipment, stream tables	Concept (BFD), PFS (PFD)	Process
P&IDs	Piping, valves, instruments, control loops	PFS preliminary, FS IFD, Execute AFC	Process with mechanical and C&I
Site and plot plans	Footprint, terraces, roads, buildings	Concept, PFS	Civil and layout
GA drawings	Equipment layout, structures, access	FS, Execute	Mechanical and structural
3D model	Integrated model, clash detection	FS about 30%, Execute 60/90% and AFC	Design
Isometrics	Pipe spools for fabrication	Execute	Piping
Single line diagrams	Power distribution and protection	PFS, FS, Execute	Electrical
Civil and structural	Foundations, concrete, steelwork	FS, Execute	Civil and structural
Mine designs	Pit stages, ramps, waste dumps, haul roads	Every phase, rising in detail	Mining

From engineering to an estimate the gate can trust

Estimators measure what engineering has drawn, price it, and add the indirect, escalation and risk layers. The estimate is then classed against how mature the engineering really is and proven alongside the schedule, risk and economics.

Estimating sequence

Step 01
Receive the engineering pack
Take a frozen snapshot of what engineering has issued.
OutputsDrawings at stated status, MEL and EEL, specifications, vendor quotes, MDR snapshot
Step 02
Plan the estimate and set the basis
Agree structure, base date, currency and exclusions.
OutputsEstimate plan, WBS and code of accounts, assumptions list
Step 03
Measure quantities
Take off quantities from drawings and the 3D model; factor where design is immature.
OutputsMaterial take-offs by commodity, growth allowances
Step 04
Price the quantities
Apply vendor prices, unit rates and labour hours.
OutputsEquipment prices, bulk rates, labour hours x productivity x rate, subcontract quotes
Step 05
Build the direct cost
Assemble priced quantities by WBS area and commodity.
OutputsDirect field cost by area
Step 06
Add indirects and owner's costs
Add the costs of managing and supporting the build.
OutputsEPCM, temporary facilities, camp, freight, spares, first fills, vendor reps, owner's team
Step 07
Escalation and exchange rates
Move the base-date estimate to when the money is spent.
OutputsEscalation by cost type, foreign exchange exposure
Step 08
Contingency from risk
Model estimate uncertainty and risk events together.
OutputsMonte Carlo QRA, P50 and P80, contingency allocation
Step 09
Classify and document
Check deliverable maturity against the class and write the basis.
OutputsEstimate class confirmed, basis of estimate document
Step 10
Validate and prove for the gate
Test the estimate and integrate it with schedule, risk and value.
OutputsBenchmarks, reconciliation to the previous estimate, independent review, gate pack

Estimate class by phase

Class	Phase	Defined	Main method	Engineering input	Accuracy range
Class 5	Concept	0 to 2%	Capacity-factored curves, parametric models, analogy	Block-flow diagram, capacity, location	-20 to -50% / +30 to +100%
Class 4	PFS	1 to 15%	Equipment-factored from a priced MEL	PFDs, preliminary MEL, site layout	-15 to -30% / +20 to +50%
Class 3	FS	10 to 40%	Semi-detailed unit costs, assembly-level take-off, vendor budget quotes	P&IDs, GAs, 3D model about 30%, specifications	-10 to -20% / +10 to +30%
Class 2	Execute (control)	30 to 75%	Detailed unit costs, forced detailed take-off, firm quotes	AFC drawings in progress, awarded packages	-5 to -15% / +5 to +20%
Class 1	Execute (check)	65 to 100%	Detailed take-off, awarded contract prices	Engineering complete	-3 to -10% / +3 to +15%

"Defined" is the share of complete project definition per AACE RP 47R-11. The class is set by deliverable maturity, not by the effort spent on the estimate.

What gets measured

Commodity	Unit	Measured from
Bulk earthworks	m3 cut and fill	Terrace, road and pad designs
Concrete	m3	Foundation and civil drawings
Reinforcing steel	t	Concrete volume x kg/m3 until bar schedules exist
Structural steel	t	GA and steel drawings, 3D model
Platework	t	Chute, bin and tank drawings
Mechanical equipment	each, priced	MEL and vendor quotes
Piping	m by diameter	Line list, isometrics
Electrical cable	m by size	Cable schedule, EEL
Instruments	each	Instrument index
Buildings	m2	Building layouts
Pre-strip Open pit	bcm	Pit design and pre-production schedule
Haul roads Open pit	km	Mine layout
Mining fleet Open pit	each, priced	Fleet schedule

How the estimate builds up

Direct field costEquipment, bulks, labour, subcontracts by WBS area

Indirect costEPCM, temporary facilities, freight, spares, first fills

Owner's costOwner's team, permits, readiness, pre-production

EscalationBase date to spend date

ContingencyFrom QRA at the chosen P-level

Total installed capitalThe number taken to the gate

Kept outside the project capital: sustaining capital, closure costs and working capital, which sit in the financial model.

Proving the case at the gate

The gate passes only when engineering, cost, schedule, risk and value tell the same story at the same maturity.

Engineering

Deliverables meet the maturity matrix for the class
Design criteria frozen
HAZOP actions closed or tracked

Cost

Basis of estimate complete
Benchmarked and reconciled to the previous estimate
Contingency at the chosen P-level

Schedule

Level matches the phase
Logic sound, critical path agreed
Schedule risk analysis done, basis of schedule written

Risk

Register current and owned
Cost and schedule risk modelled together
Opportunities captured

Value

Financial model uses the latest capex, opex and schedule
NPV and IRR against the hurdle
Sensitivities and break-evens shown

Readiness

Permits on track
Execution plan and contracting strategy approved
Owner's team and funding in place

Deliverable maturity by phase

What each deliverable must reach before its gate. This is how a study proves it is truly PFS or FS ready, and how the estimate class is checked against the engineering behind it.

-Not requiredSStartedPPreliminaryDDefined for decisionFFinal or AFC

Deliverable	Concept G1	PFS G2	FS G3	Execute G4
Scope and strategy
Objectives charter	P	D	F	F
Scope definition and battery limits	S	P	D	F
WBS and code of accounts	S	P	D	F
Project execution plan	-	S	D	F
Contracting strategy	-	S	D	F
Resource and mining
Geological and resource model	P	D	D	F
Mineral Reserve	-	D	F	F
Life-of-mine plan and schedule	S	P	D	F
Geotechnical model	S	P	D	F
Hydrogeology and dewatering	S	P	D	F
Mining design Open pit
Pit optimisation and staging	P	D	F	F
Pit slope design	S	P	D	F
Waste dumps and haul roads	S	P	D	F
Mining fleet schedule	S	P	D	F
Process
Metallurgical testwork	S	P	D	F
Process design criteria	S	P	D	F
Block-flow and PFDs	P	D	F	F
Mass and water balance	S	P	D	F
P&IDs	-	S	D	F
Equipment datasheets	-	S	D	F
Equipment lists
Mechanical equipment list (MEL)	S	P	D	F
Electrical equipment and load list (EEL)	-	P	D	F
Instrument index	-	-	P	F
Vendor quotes	-	S	D	F
Layouts and drafting
Site and plot plans	S	P	D	F
GA drawings	-	S	D	F
3D model	-	S	P	F
Piping isometrics	-	-	S	F
Single line diagrams	-	S	D	F
Civil and structural drawings	-	S	P	F
Master drawing register	-	S	D	F
Infrastructure
Site geotechnical investigation	-	S	D	F
Tailings storage facility design	S	P	D	F
Power supply	S	P	D	F
Water supply	S	P	D	F
Logistics	S	P	D	F
Controls and approvals
Capital estimate	C5	C4	C3	C2
Schedule	L1	L2	L3	L4
Risk register	S	P	D	F
Cost and schedule QRA	-	S	D	F
Financial model	P	D	D	F
Permits and licences	-	S	D	F

Levels are typical for a greenfields mining project and follow the intent of the AACE RP 47R-11 maturity matrix. The client's own stage-gate standard takes precedence where it is stricter.

Estimate classes and accuracy ranges follow AACE International RP 47R-11 (mining and mineral processing) and 18R-97. Reserve terms follow the SAMREC Code (2016).

Planning a mine project?

We set up the controls that carry a project through every gate: estimates classed to engineering maturity, integrated schedules, and risk and value tracked together.

Book a controls review Project controls services

Controls. Intelligence. Delivered.

AI-Integrated Project Controls and Planning

Mine Delivery Roadmap

Lifecycle roadmap

Key activities

Key deliverables

Mining scope Open pit

Project controls

Exit gate

From business need to packages of work

Safety

Production

Recovery and product

Value

Capital and schedule

Licence to operate

Life of mine

Scope statement

Battery limits

Scope book

Interfaces

Assumptions and exclusions

Mining Open pit

Process plant

Tailings and water

Site infrastructure

Off-site infrastructure

Indirects

Owner's costs

Contingency and escalation

Engineering

Design and drafting

Procurement

Construction

Project controls

Commissioning

Owner's team

Typical contract packages (all mines)

Mining packages Open pit

Traceability: objective to package

How engineering is developed

Generic hard-rock flowsheet

Open pit

Haulage

ROM pad

Primary crushing

Conveying and stockpile

Secondary and tertiary

Grinding

Separation

Dewatering and product

Engineering development sequence

Basis of design and design criteria

Testwork and process modelling

Trade-off studies

Process flow diagrams

Equipment selection

Equipment and engineering lists

Specifications and drawing register

Drafting and 3D modelling

Reviews

Approval and release

Trade-off studies typically run

All mines

Mining Open pit

Document status ladder

Drafting set

From engineering to an estimate the gate can trust

Estimating sequence

Receive the engineering pack

Plan the estimate and set the basis

Measure quantities

Price the quantities

Build the direct cost

Add indirects and owner's costs

Escalation and exchange rates

Contingency from risk

Classify and document

Validate and prove for the gate

Estimate class by phase

What gets measured

How the estimate builds up