Tailings management describes the engineered containment, sealing and long-term storage of mineral processing waste in tailings storage facilities (TSFs). Uncontrolled leachate infiltration and structural berm failure pose severe environmental and reputational risks. Carbofol® + geomembranes, Bentofix® + X geosynthetic clay liners (GCLs), Secutex® protection nonwovens, Secudrain® drainage composites and Secugrid® geogrids provide a proven, integrated system solution for every phase of a TSF from base lining to closure capping.
Naue geosynthetics seal, reinforce and drain tailings storage facilities throughout their entire life cycle - from base lining and berm stabilisation to final closure.
Secure tailings and process residues with impermeable lining systems that protect soil and groundwater.
Multi-layer capping with Carbofol®, Bentofix® and Secudrain® isolates closed tailings ponds and lagoons, reduces infiltration and supports revegetation.
Reinforce perimeter berms and slopes for structural stability under high tailings loads.
Geocomposite drainage layers for controlled water management within and above the lining.
TSF lining systems must perform across the full mine life, often exceeding 50 years. Carbofol® HDPE geomembranes are formulated with exceptional UV, stress-crack and chemical resistance. Secutex® nonwoven geotextiles provide both puncture protection for the geomembrane and friction stability on steep slopes.
Practical advantages:
Regulatory requirements, leachate aggressiveness, hydrogeological sensitivity and pond depth determine the appropriate lining system for a tailings storage facility. Naue provides all components for single, composite and double liner configurations from one source.
Key Principle: A geomembrane seals the pond. A GCL adds a secondary mineral barrier. A drainage geocomposite manages water above gas below the liner. All three layers may be needed simultaneously.
The choice of primary liner depends on leachate chemistry, subgrade conditions, regulatory requirements and long-term performance targets. This table provides a direct comparison across the most critical design criteria.
| Design criterion | Carbofol® HDPE | Bentofix® GCL | Composite: HDPE + GCL | Recommended when |
|---|---|---|---|---|
| Hydraulic performance | k ≤ 10⁻¹² m/s (HDPE geomembrane) | k ≤ 5 x 10⁻¹¹ m/s (GCL alone) | k ≤ 10⁻¹² m/s (composite) | Single barrier: Carbofol®. Secondary mineral layer required: add Bentofix® |
| Chemical resistance | Excellent; HDPE highly resistant to a wide pH range | Caution: Standard sodium bentonite GCL (Bentofix®) is unsuitable where tailings leachate pH < 4 or where high concentrations of polyvalent cations (Ca2+, Mg2+, heavy metals) are present. Specify Bentofix® X (polymer-coated) or Carbofol® HDPE-only barrier for acidic or heavy-metal tailings. | Best; HDPE provides primary chemical barrier; GCL secondary backup | Always use Carbofol® HDPE as the primary barrier in acidic or heavy-metal leachate. For a secondary GCL barrier in acidic tailings (pH < 4) or high polyvalent cation environments, specify Bentofix® X (polymer-coated grade). Standard Bentofix® grades are not suitable under these conditions. |
| Subgrade requirement | Compacted, sharp-free subgrade or Secutex® protection layer mandatory | Requires moisture for hydration; performs well on irregular subgrades | Most adaptable - GCL conforms to uneven surfaces; HDPE provides impermeability | Rocky or uneven subgrade: composite system preferred |
| Installation on steep slopes | Available with textured surface for improved friction angle | Reinforced needle-punched construction increases shear strength | Secugrid® or Secutex® may be required for frictional stability | Slopes > 30°: consult Naue engineering for composite system stability analysis |
| Self-healing/redundancy | Not self-healing — weld integrity via CQA and air-channel testing | Self-sealing bentonite swells to close minor damage | Self-sealing GCL provides a redundancy layer for any HDPE defect | High-consequence TSFs (deep ponds, sensitive sites): composite mandatory |
| Closure and capping | Carbofol® suitable as an impermeable barrier in a capping system | Bentofix® used as a capping mineral barrier; self-sealing supports post-closure performance | Composite capping for highest performance: Carbofol® + Bentofix® + Secudrain® | Closure of active TSF: composite system recommended per MAC TSF Guidelines |
Proven performance in aggressive mining environments
Carbofol® HDPE geomembranes have documented performance in acid mine drainage (AMD), gold cyanide leach and copper sulphate environments. Bentofix® GCLs deliver k ≤ 5 x 10⁻¹¹ m/s as a mineral barrier layer in composite systems.
Structural safety of perimeter berms
Secugrid® and Combigrid® geogrids reinforce tailings pond berms against saturation, erosion and slope failure. Their high-strength welded junctions maintain reinforcement integrity even under the chemical and biological threats of a mining environment.
Reduce total cost of ownership
Replacing a compacted clay liner (CCL) of 0.6 - 1.0 m thickness with a Bentofix® GCL layer of approximately 6 - 8 mm significantly reduces material volumes, transport, earthworks and construction time.
TSF closure and recultivation support
Naue capping systems use Carbofol® geomembranes, Bentofix® GCLs and Secudrain® drainage geocomposites to isolate closed TSFs over the long term. The system greatly reduces infiltration, helps prevent polluted runoff and supports healthy vegetation re-establishment.
A tailings storage facility (TSF) is an engineered structure that permanently stores mineral processing waste (tailings) after valuable metals or minerals have been extracted. Tailings typically contain residual reagents, heavy metals and process water. Geosynthetics - primarily geomembranes, GCLs, geotextiles and drainage composites - form the impermeable barrier system that prevents these contaminants from reaching groundwater and surrounding soil.
The core Naue product range for TSF lining comprises: Carbofol® HDPE geomembranes (primary polymeric barrier), Bentofix® GCLs (mineral secondary barrier), Secutex® nonwoven geotextiles (protection and filtration), Secudrain® geocomposite drainage systems and Secugrid®/Combigrid® geogrids (berm and slope reinforcement). These products can be configured as single, composite or double liner systems depending on project requirements.
TSF design is governed by international guidelines, including ICOLD Bulletin 121 (Tailing Dams - Risk of Dangerous Occurrences), MAC (Mining Association of Canada) TSF Design Guidelines, ASTM D5887 (GCL permeability), and GRI GM13 (HDPE geomembrane properties). National regulations in Germany additionally require BAM approval for geosynthetics used in containment applications. Naue products carry the required certifications and approvals. At the facility level, tailings storage is increasingly expected to conform to the Global Industry Standard on Tailings Management (GISTM); Naue geosynthetic systems support the containment and closure performance objectives within a GISTM-conformant facility.
A Bentofix® GCL with a thickness of approximately 6 - 8 mm replaces a compacted clay liner (CCL) of 0.6 - 1.0 m. This reduces earthworks volumes, on-site compaction plant requirements and construction time significantly. Transport of bentonite granules to remote mine sites is substantially easier than transporting and compacting equivalent volumes of clay.
Installation on steep and rocky TSF slopes requires specialist geosynthetics installers following Naue installation manuals and a site-specific CQA (Construction Quality Assurance) plan. For slopes exceeding 45° or near-vertical rock sections, geosynthetics are anchored using cemented rock bolts or anchor trenches. Carbofol® geomembrane welds are performed by certified welders using double-weld hot-wedge equipment. Air-channel pressure testing verifies every weld seam.
Requirements vary by jurisdiction. Internationally, ICOLD Bulletin 121 and MAC TSF Design Guidelines set the benchmark for safety and performance. In Germany, geosynthetics for containment applications require BAM approval under the German waste regulation framework. Key performance criteria include geomembrane permeability (k ≤ 10⁻¹² m/s), GCL hydraulic conductivity (k ≤ 5 x 10⁻¹¹ m/s in accordance with ASTM D5887), chemical compatibility with the specific leachate and long-term durability. Naue provides full documentation packages to support regulatory submissions.
Yes. Naue products have been deployed in numerous mining projects globally, including gold mine TSFs in the Middle East, copper tailings ponds in South America and phosphate impoundments in Europe. Reference projects include a major TSF expansion project where more than 300,000 m2 of Naue products (Bentofix®, Carbofol®, Secudrain®, Secutex®) were supplied and installed in a single application. Please also visit our case studies.
TSF closure involves placing a multi-layer capping system over the tailings mass to isolate contaminants over the long term. A typical Naue capping system comprises Carbofol® HDPE geomembrane as the impermeable barrier, Bentofix® GCL as the secondary mineral seal, and Secudrain® drainage geocomposite to manage infiltration in the cover soil. This system greatly reduces long-term seepage, helps prevent polluted runoff and creates a stable platform for revegetation and ecological recovery of the former mine site.
Carbofol® geomembrane seams are produced by certified welders using dual-channel hot-wedge welding machines. Every weld channel is immediately pressure-tested with compressed air - any seam failing the pressure test is repaired and retested. A complete weld log records each seam by position, welder ID, date, test result and repair history. This CQA (Construction Quality Assurance) record is submitted to the project engineer and regulatory body as evidence of compliant installation on all TSF projects.
TSF lining systems are dimensioned in accordance with recognised international standards. Naue engineering support assists mine operators and their consultants in selecting the appropriate system configuration for their specific project conditions.
Naue Carbofol® + HDPE geomembrane is an enhanced oxidation-resistant liner for mining containment, landfill sealing and other critical barriers.
Naue Bentofix® + X is a Thermal Lock GCL with enhanced oxidative resistance for mining, landfill and hydraulic engineering.
Naue Secutex® is a mechanically bonded nonwoven geotextile for separation, filtration and protection for the use in roads, railways, environmental and hydraulic engineering projects.
Naue Secudrain® is a geosynthetic drainage geocomposite for landfill, groundwater protection and building structures.
Naue Secugrid® geogrid stabilises and reinforces roads, embankments, working platforms, slopes and walls.
