Removal of geosynthetics
Clean separation, safe roll-up with the Naue spreader bar
The Naue removal spreader bar is a hydraulically driven excavator attachment that recovers Secugrid®, Combigrid®, Secutex® and other geosynthetics from temporary site roads, working platforms and storage areas — pulling them out under controlled tension, separating the base course aggregate cleanly and winding the geosynthetic onto a core. The result: the aggregate can be reused on the next site, the geosynthetic rolls are sent for reuse or single-stream recycling, and the deconstruction process is fast, mechanised and labour-efficient.
At a glance
- Service - Mechanised removal of installed geosynthetics — clean separation of aggregate and roll-up of the geosynthetic under controlled tension.
- Equipment - Naue removal spreader bar — a hydraulically driven excavator attachment.
- Recovered materials - Secugrid®, Combigrid®, Secutex® and other Naue geosynthetics; base course aggregate as a clean, reusable stream.
- Typical use - Temporary site roads, working platforms, storage and laydown areas, test sections and pilot installations.
- Outcome - Aggregate is reused on the next site; geosynthetic is sent for reuse or single-stream recycling; fewer disposal and haulage movements.
Mechanised removal: from mixed waste to two reusable streams challenges solution outcome
Challenges
- Manual lifting of geosynthetics - slow, costly, mixed material
- Mixed aggregate / geosynthetic waste in skips
- Damaged, incorrectly rolled geosynthetic that is hard to recycle
- Disposal costs and CO₂ emissions from haulage to landfill
Solution
- The removal spreader bar pulls and rolls the geosynthetic under controlled tension
- Clean separation as the base course is lifted clear of the panels
- Controlled tension and core-winding deliver tidy, single-stream rolls
- Two reusable streams replace mixed waste
Outcome
- Mechanised, predictable cycle times for a labour-efficient operation.
- Aggregate available for direct reuse - no remediation required.
- Recyclable polyolefin/polyester rolls or reuse in a new project.
- Fewer lorry movements and lower disposal costs, quantified per project in the removal log.
Where the Naue removal spreader bar is used
The removal spreader bar is engineered for projects where geosynthetics have been installed for temporary load distribution and now need to be recovered cleanly.
Temporary site roads
Recover Combigrid® and Secutex® from haul roads and access tracks at the end of the construction phase. Aggregate can be reused on the next site road; geosynthetic rolls are sent for reuse or recycling.
Working platforms (cranes, piling, drilling)
Recover Secugrid® and Combigrid® from working platforms beneath cranes, piling rigs and drilling equipment. Roll-up under controlled tension preserves the geogrid for reuse where appropriate.
Storage and laydown areas
Recover Secutex® and Combigrid® from material storage and laydown areas at the end of long-running projects. Clean aggregate becomes the next sub-base - with no off-site disposal required.
Test sections and pilot installations
Recover instrumented Secugrid® and Combigrid® panels from test sections after monitoring is complete, preserving panel integrity for laboratory analysis or further trials.
Decommissioning of geosynthetic systems
Support the decommissioning of yard surfaces, temporary noise walls and short-life logistics infrastructure - clean removal as part of the site reinstatement plan.
Removal of geosynthetics: technical detail
Process sequence - pull, separate, roll
The Naue removal spreader bar follows a fixed three-step sequence: pulling the geosynthetic out from beneath the base course, separating the aggregate cleanly as the panel is lifted, and winding the panel onto a core under controlled tension. Cycle times are predictable, manual handling is minimal, and the two output streams are immediately reusable.
Practical advantages for site teams:
- Hydraulically driven attachment — fits standard tracked excavators (subject to project-specific carrier confirmation).
- Predictable cycle times — typical roll-up rate measured in minutes per panel, not hours.
- Clean separation — aggregate is available for direct reuse on the next site road or platform.
- Controlled tension prevents tearing and incorrect rolling — preserving the geosynthetic for reuse where possible.
- Reduced manual handling — fewer manual lifting operations, lower HSE risk.
Step-by-step removal sequence:
- The excavator removes the bulk of the base course material with a flat shovel positioned close to the geosynthetic panel.
- The spreader bar attachment is lowered and engages the leading edge of the geosynthetic.
- The panel is pulled out under slight tension — residual aggregate slides off cleanly.
- The spreader bar winds the panel onto a core to a predefined diameter.
- The core is lifted and stockpiled; the next panel is engaged and the cycle repeats.
- At the end of the shift, the recovered aggregate and the geosynthetic rolls are documented and routed to reuse or recycling.
Mechanised removal vs. manual removal — Why it matters
Manual removal of installed geosynthetics is slow, labour-intensive and often results in mixed aggregate / geosynthetic waste that is hard to reuse. The Naue removal spreader bar replaces that workflow with a mechanised process that produces two clean, reusable streams.
Key principle: Mechanised removal protects two value streams in a single pass — the recovered aggregate,and the geosynthetic itself. Manual removal compromises both.
Manual Removal
- Manual lifting of small panel sections
- Variable, unpredictable site rates
- Aggregate and geosynthetic mixed in the skip
- Damage to panels reduces recyclability
- Best for: very short-run, small-area recoveries.
Naue Removal Spreader Bar
- Mechanised pull-and-roll process with the Naue spreader bar
- Predictable cycle times; documented site rates
- Two clean output streams: aggregate and geosynthetic
- Controlled tension preserves the geosynthetic for reuse
- Best for: site roads, working platforms, storage areas and test sections.
Reuse or recycle? Decision guide for recovered geosynthetics
Whether a recovered geosynthetic is best reused as a panel on a follow-on project, or returned to a recycling partner as single-stream raw material, depends on its installed history, residual condition and the receiving project. Naue assesses each consignment and routes it accordingly.
| Criterion | Reuse Pathway |
|---|---|
| Installed loading | Light to moderate — temporary site road, storage yard, pilot installation. |
| Residual condition | Tidy roll, no major tearing, no chemical or hydrocarbon contamination. |
| Documented history | Site logs, installation date, removal date and aggregate compatibility recorded. |
| Onward project | Suitable application identified — e.g. follow-on site road, working platform. |
| Recommended use | Direct reuse on the next site, with sign-off from Naue Engineering Support. |
| Criterion | Recycling Pathway |
|---|---|
| Installed loading | Heavy or long-duration loading — significant mechanical history. |
| Residual condition | Tearing, contamination or unsuitabililty for further structural use. |
| Polymer family | Mono-material polyolefin (PE, PP) or polyester (PET) — single stream return. |
| Onward project | Recycling partner accepts the polymer family in single-stream rolls. |
| Recommended use | Single-stream recycling — Naue coordinates the onward logistics. |
Benefits from the site, client and sustainability officer perspective
Why contractors, public clients and sustainability officers specify the Naue removal spreader bar.
Material recovery
Two reusable streams (aggregate and geosynthetic) instead of mixed waste — lower disposal volumes, recorded per project.
Cost reduction
Lower disposal costs, lower haulage costs, immediate aggregate reuse on the next site road.
Predictable schedule
Mechanised cycle times deliver reliable removal rates per shift.
HSE improvement
Less manual lifting reduces HSE exposure and the likelihood of incidents.
Removal of geosynthetics using spreader bar – Clean separation and safe roll-up
How the removal spreader bar works in the deconstruction sequence
- Bulk aggregate removal: a flat-shovel excavator clears the upper aggregate close to the geosynthetic surface without cutting into the panel.
- Panel engagement: the spreader bar attachment engages the leading edge of the geosynthetic panel.
- Controlled pull: the panel is lifted under slight tension; residual aggregate slides off the geosynthetic.
- Core winding: the spreader bar winds the panel onto a core to a predefined diameter under controlled tension to prevent damage.
- Two output streams: clean aggregate stockpile for direct reuse; recovered geosynthetic rolls for reuse or single-stream recycling.
The development of this deconstruction method is part of the KuRT.
ProGeo-UP research project, funded by the German Federal Ministry of Research, Technology and Space (BMFTR) under grant number 033R391G.
Removal of geosynthetics: frequently asked questions
The removal spreader bar is a hydraulically driven excavator attachment that pulls installed geosynthetics out from beneath the base course, separates the aggregate cleanly and winds the geosynthetic onto a core under controlled tension. It is engineered for low-waste, mechanised deconstruction of site roads, working platforms and storage areas.
The spreader bar is qualified for Naue Secugrid®, Combigrid® and Secutex® and works with comparable polymer geosynthetics from other manufacturers. Project-specific suitability is confirmed with the Naue application engineering team.
In many cases yes. Clean separation during the lift means the aggregate is available for direct reuse on the next site road, working platform or sub-base — without remediation or screening in most cases.
In many cases yes — particularly on temporary structures with light to moderate loading and no contamination. Naue assesses each consignment and routes it to direct reuse or to single-stream recycling.
Mono-material polyolefin (PE, PP) and polyester (PET) geosynthetics are recyclable as single streams. Naue coordinates the onward route to the recycling partner.
The spreader bar is designed for standard tracked excavators in the typical earthmoving size range. Project-specific carrier confirmation is provided as part of the planning phase.
Cycle times are predictable and faster than manual removal. Typical site rates are confirmed by the application engineering team based on panel size, aggregate type and excavator carrier.
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