Project: West Wits Mining - ROM Ore Pads
Location: South Africa
Completion Date: February 2026
Contractor: Geosynthetics South Africa Pty Ltd

Geosynthetics Africa was engaged to deliver a fully engineered geomembrane containment system for ROM ore pads, including supply, logistics, installation, and full QA/QC verification.

The project required a load-bearing, puncture-resistant containment solution capable of withstanding:

• Continuous heavy equipment traffic
• High static and dynamic ore loads
• Environmental exposure
• Strict containment compliance

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ENGINEERED SYSTEM DESIGN

This was not a standard liner installation , it was a multi-layer engineered containment system designed for mining operations.

System Cross-Section (Bottom to Top)

✔ Designed for high load mining environments
✔ Engineered to prevent puncture, deformation, and leakage
✔ Fully aligned with GRI-GM13 geomembrane standards

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CRITICAL ENGINEERING FEATURES

1. Anchor Trench System

• 150 × 150 mm anchor trench on three sides
• Provides long-term liner restraint
• Prevents uplift and edge instability

2. Drainage Control System

• Perimeter drainage trench (lined)
• Controls runoff and prevents contamination migration

3. Concrete Hump Interface 

Engineering Purpose:

• Controls surface water ingress
• Protects liner at high-risk entry zone
• Provides traffic transition from haul road to lined pad
• Acts as a termination and interface boundary

Geosynthetics Africa integrated the geomembrane system into this feature, ensuring:

• Controlled liner termination
• Protection against shear stress
• Long-term durability at the most critical interface

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MATERIALS SUPPLIED & INSTALLED

Geomembrane

• Product: GSE HDPE Geomembrane
• Thickness: 1.5 mm (approved upgrade from 1.25 mm)
• Standard: GRI-GM13 compliant
• Manufacturer: GSE / Solmax

Geotextile Protection

• Product: MIRAFI S82 Nonwoven
• Function: Cushioning + puncture resistance + separation

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TRACEABILITY & MATERIAL CONTROL

All materials were:

• Manufactured in ISO-certified facilities
• Fully batch traceable
• Delivered in original labelled rolls
• Verified against factory QA documentation

📌 Full traceability records maintained in QA system

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INSTALLATION METHODOLOGY

• GSE Manufacturer Guidelines
• Group IAGI Installer Member: Geosynthetics Africa holds the membership, and Geosynthetics South Africa follows the group's installation and QA/QC procedures.
• Project-Specific Method Statements

Execution Sequence

1. Subgrade Preparation

• Inspection and approval of prepared surface
• Removal of sharp materials
• Placement of controlled sand bedding

2. Liner Deployment

• Panels installed along wind direction
• Minimum 100 mm overlaps

3. Welding Operations

• Dual-track hot wedge welding
• Extrusion welding for details and repairs

4. Protection Layer Installation

• MIRAFI S82 placed over liner
• Ensured full coverage prior to loading

5. Final Layer Placement

• Controlled placement of sand and crushed material

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WELDING & QA/QC CONTROL

Equipment

• Leister Hot Wedge Welders
• Leister Extrusion Welders
• Vacuum Testing Units
• Air Pressure Testing Systems

Welding Procedure

• Six trial welds performed
• Optimal parameters selected (temperature, speed, pressure)
• Continuous monitoring and recalibration

📌 Trial weld optimisation confirmed before production

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QUALITY ASSURANCE & TESTING

• Air Pressure Testing (double seam)
• Vacuum Box Testing
• Visual Inspection
• Trial Weld Testing

Acceptance Criteria

• Continuous weld integrity
• Zero leakage
• No voids or defects

Results

• 100% seam testing completed
• One localized defect repaired and retested
• Full system integrity confirmed

📌 Installation certified compliant post-testing

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HEALTH, SAFETY & ENVIRONMENTAL PERFORMANCE

• Zero incidents recorded
• Full PPE compliance
• Controlled work zones
• Strict liner protection protocols

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PROJECT OUTCOME

✔ Fully engineered containment system delivered
✔ Installation compliant with international standards
✔ Integrated civil + geosynthetic system executed successfully
✔ System approved for operational use

📌 Final sign-off confirms compliance with all specifications

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STRATEGIC PROJECT SIGNIFICANCE

This project demonstrates Geosynthetics Africa’s capability to deliver:

1. Load-Bearing Mining Containment Systems

Not just liners - engineered operational platforms

2. Civil + Geosynthetic Integration

• Concrete interface (hump)
• Drainage systems
• Anchor trench systems

3. Full Lifecycle QA/QC

• Material traceability
• Installation QA
• Testing verification

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Why choose Geosynthetics South Africa?

We are a specialist geosynthetics engineering contractor delivering:

• HDPE Geomembrane Systems (GSE / Solmax)
• Geotextile Protection Systems (MIRAFI)
• IAGI-Compliant Installation
• Pan-African Delivery Capability

Applications

• ROM Pads
• Heap Leach Pads
• Tailings Storage Facilities
• Water Containment Systems

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Geosynthetics Africa delivers engineered containment systems - not just liners.

From material supply to final QA certification, we ensure:

✔ Structural performance
✔ Environmental compliance
✔ Long-term durability

Trusted by mines. Proven in the field. Built for Africa.

GCL & HDPE Geocell Lining of Stormwater Attenuation Pond

Total Fuel Depot Expansion - South Africa

Project Overview

As part of the Total Fuel Depot Expansion in South Africa, a new stormwater attenuation pond was required to manage runoff and ensure environmentally compliant containment within a sensitive fuel storage and handling facility. The project demanded a high-integrity containment solution capable of accommodating steep side slopes, strict environmental controls, and long-term performance requirements.

Geosynthetics Africa was appointed to supply, deliver, and install the complete lining system, including a reinforced geosynthetic clay liner (GCL) and HDPE geocell slope stabilisation, executed by a qualified installation crew under IAGI-aligned installation procedures.

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Engineering & Environmental Challenges

The attenuation pond design presented several technical challenges:

• Steep embankment slopes, requiring slope stabilisation and erosion control

• Requirement for perfect containment, with zero tolerance for leakage due to proximity to fuel infrastructure

• Stormwater management compliance, aligned with civil drainage and environmental specifications

• Need for rapid mobilisation, supported by immediate material availability

• Installation to be completed by a competent, experienced geosynthetics contractor

Traditional unreinforced clay lining systems were unsuitable due to slope geometry and constructability risks. A composite geosynthetic solution was therefore adopted.

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Geosynthetics Africa Solution

High-Performance GCL Containment

The primary containment layer comprised Eurobent® EB4000, a reinforced geosynthetic clay liner (GCL) incorporating sodium bentonite encapsulated between geotextiles and mechanically reinforced to enhance internal shear strength.

This provided:

• Low hydraulic conductivity for stormwater containment

• Excellent self-sealing performance around penetrations and minor damage

• Compatibility with steep slope applications

• Rapid installation compared to compacted clay alternatives

HDPE Geocell Slope Stabilisation

To address slope stability and long-term erosion control, HDPE geocell was installed over the GCL on the embankments. The geocell system allowed:

• Load confinement and slope stabilisation

• Placement of topsoil infill to support vegetation

• Long-term erosion resistance under stormwater flow conditions

• Protection of the underlying GCL from UV exposure and mechanical damage

This combined system delivered both structural stability and environmental integration, essential for fuel depot infrastructure.

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Installation & Quality Assurance

The project required qualified installers and strict adherence to best-practice installation standards.

Geosynthetics Africa provided:

• Immediate stock availability of Eurobent® EB4000 GCL and HDPE geocell from regional inventory

• A trained and experienced installation crew

• Installation procedures aligned with IAGI (International Association of Geosynthetic Installers) guidelines

• Controlled placement, seaming, and anchorage of the GCL

• Careful coordination between GCL installation and geocell deployment on steep slopes

This ensured the attenuation pond was constructed to meet engineering design intent, environmental compliance requirements, and long-term durability expectations.

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Project Outcomes

• ✔ Fully lined stormwater attenuation pond with high-integrity containment

• ✔ Stable, vegetated slopes achieved using HDPE geocell

• ✔ Compliance with civil, environmental, and fuel depot infrastructure standards

• ✔ Rapid execution supported by immediate material availability

• ✔ Installation delivered by a qualified, IAGI-aligned contractor

The project demonstrates Geosynthetics Africa’s capability to deliver complex containment systems for fuel, energy, and industrial infrastructure projects across Southern Africa.

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Products Used on This Project

 

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Group expertise through Geosynthetics South Africa

Geosynthetics Africa supplies and installs high-performance geosynthetic solutions for fuel, mining, water, waste, and infrastructure projects across Africa. With regional stockholding, technically qualified installation teams, and IAGI-aligned installation processes, the company supports both planned works and time-critical projects requiring assured quality and compliance.

Amsterdam Bulk Water Supply Scheme - Phase 4

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Project Overview

The Amsterdam Bulk Water Supply Scheme - Phase 4 forms part of a critical municipal infrastructure programme aimed at strengthening long-term water security through major civil and earthworks construction.
As with many bulk water and municipal infrastructure projects in South Africa, construction activities were required to proceed over variable and locally weak subgrade soils, presenting challenges related to load support, constructability, and material efficiency.

To address these challenges, Tensar® Biaxial Geogrid TGSG 20 was deployed as a soil stabilisation and ground improvement solution, enabling improved subgrade performance while optimising the use of imported aggregates.

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Engineering Challenge: Weak Subgrades & Material Efficiency

Bulk water infrastructure projects typically involve:

• Extensive earthworks and platform construction

• Heavy construction traffic and plant movement

• Access roads, working platforms, and structural layers built over marginal soils

On this project, untreated subgrade conditions presented a risk of:

• Excessive rutting and deformation

• Reduced bearing capacity under construction loads

• Increased dependence on thick aggregate layers to achieve stability

Traditional “dig-and-replace” approaches would have resulted in higher aggregate volumes, increased haulage, extended construction timeframes, and elevated project costs.

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Geotechnical Solution: Tensar® Biaxial Geogrid TGSG 20

To mitigate these risks, Tensar® Biaxial Geogrid TGSG 20 was incorporated into the pavement and working platform build-up to form a Mechanically Stabilised Layer (MSL).

Why Tensar TGSG 20

Tensar TGSG 20 is a biaxial polypropylene geogrid engineered to stabilise soils and aggregates by:

• Promoting mechanical interlock between aggregate particles

• Restricting lateral movement under applied loads

• Increasing the effective stiffness of the composite soil-aggregate layer

• Improving load distribution across weaker subgrades

This performance mechanism is well documented by Tensar International for roads, working platforms, access routes, and infrastructure foundations.

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Application & Installation Overview

The geogrid was installed directly over prepared subgrade surfaces, followed by placement and compaction of engineered aggregate layers in accordance with recognised geosynthetics installation practices.

Typical installation methodology included:

1. Subgrade preparation to line and level

2. Placement of Tensar TGSG 20 biaxial geogrid over weak soils

3. Correct overlap and alignment to ensure continuity of reinforcement

4. Placement of aggregate cover layer

5. Compaction to specification to activate interlock

This approach allowed the formation of a stable working platform capable of supporting construction loads while limiting deformation.

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Performance Outcomes

Improved Soil Stability

The use of Tensar TGSG 20 significantly enhanced subgrade performance by creating a reinforced composite layer that improved bearing capacity and resistance to deformation.

Optimised Aggregate Usage

Consistent with Tensar International design guidance, the stabilised layer enabled reduced reliance on excessive aggregate thicknesses when compared to unreinforced construction over weak soils.
This translated into material efficiency benefits without compromising performance.

Tensar International documentation confirms that biaxial geogrids are routinely used to reduce aggregate demand and improve pavement efficiency on weak subgrades; however, achievable reductions are project-specific and design-dependent.

Enhanced Constructability

Stable working platforms improved site trafficability, reduced construction delays, and supported efficient progress of civil works.

Long-Term Infrastructure Performance

Improved load distribution and confinement contribute to the durability and serviceability of infrastructure layers over the design life of the asset.

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Role of Geosynthetics Africa

Geosynthetics Africa supplied Tensar® Biaxial Geogrid TGSG 20 as part of its broader capability to support soil stabilisation, ground improvement, and civil infrastructure projects across South Africa and the African continent.

With extensive experience in geogrids, geomembranes, geotextiles, and engineered geosynthetic systems, Geosynthetics Africa supports projects from design alignment through to material supply and technical support, ensuring solutions are aligned with international best practice.

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Conclusion

This project demonstrates the proven effectiveness of Tensar® Biaxial Geogrid TGSG 20 for soil stabilisation in municipal bulk water infrastructure applications.
By reinforcing weak subgrades and optimising aggregate usage, the geogrid solution delivered improved constructability, material efficiency, and long-term performance.

Geogrid-based stabilisation remains a cost-effective, technically robust solution for civil, municipal, mining, and infrastructure projects across Southern Africa.

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Products Supplied

 📄 Download Full Case Study (PDF)

Scope: Potable water Lining of leaking concrete water reservoir

Location: Rustenburg, North West Province, South Africa

Client: Rustenburg Municipality

Project: Concrete Potable Water Reservoir Tank Lining
Installer & Supplier: Geosynthetics Africa (Pty) Ltd
Completion: On Time & Within Budget

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The Problem: Aging Concrete and Water Contamination Risks

Municipalities across South Africa are facing a critical need to extend the lifespan of aging infrastructure while maintaining the integrity of potable water supply systems. Rustenburg Municipality faced similar challenges with a concrete reservoir tank that had begun showing signs of deterioration - including micro-cracking, water seepage, and increased risk of contamination. Traditional waterproofing methods were proving unsustainable, and compliance with potable water safety standards became a top priority.

The tank needed a permanent, hygienic, and certified lining solution that could withstand the internal hydraulic pressure, bond securely to vertical concrete walls, and meet South African drinking water regulations.

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The Solution: Certified PVC Lining System by Geosynthetics Africa

Geosynthetics Africa was selected as the preferred contractor due to our unmatched technical expertise, rapid deployment capacity, and proven track record in potable water containment systems across Africa. We designed and implemented a full lining system that delivered both long-term performance and compliance with SANS potable water standards.

Our approach ensured:

• • Full tank encapsulation using a certified potable water liner

• • Protection of the liner from concrete abrasion

• • Reinforcement on vertical surfaces for mechanical security

• • Dual sealing through glue application and thermal welding

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Scope of Work Included:

• • Surface preparation of internal concrete walls and floor

• • Installation of Mirafi Liner Protection Geotextile to prevent abrasion and punctures

• • Custom-fit lining using PVC 720gsm Potable Water Grade Liner

• • Application of Vertical Concrete Wall Reinforcement Anchors to secure vertical liner placement

• • Use of Geosynthetics Africa’s proprietary PVC Glue for high bond strength adhesion

• • Hot Air Welding and Testing of seams to ensure leak-proof connections

• • Final QA/QC inspections in line with municipal and SANS 1731 standards

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Products Used on This Project

Product	Description
PVC 720gsm Potable Water Grade Liner	Certified for direct contact with drinking water; UV-stabilised and chemically inert
Mirafi 400gsm Geotextile Underlay	High-strength, needle-punched protection layer beneath the liner to prevent mechanical damage
Vertical Wall Liner Reinforcement System	Secure anchoring detail for vertical surfaces to resist delamination and liner displacement
Geosynthetics Africa’s PVC Glue	Engineered for water tank applications with enhanced adhesion properties on concrete substrates
Heat Welding Equipment	Precision thermal welding to create seamless, leak-proof joints across liner panels

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Why choose Geosynthetics South Africa?

Geosynthetics Africa (Pty) Ltd has become the go-to partner for reservoir lining and geomembrane systems across Southern, Central, East, and West Africa. With experience spanning mining, municipal infrastructure, agriculture, and industrial containment, we are Africa’s leading supplier and installer of high-performance water containment systems.

We don’t just install liners - we provide engineered containment solutions, backed by decades of geosynthetics expertise, quality assurance, and after-sales support.

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Looking to Line Your Water Tank or Reservoir?

Whether it’s a concrete tank refurbishment, dam lining, or pond sealing - Geosynthetics Africa is your first choice across Africa.

📩 Email: sales@geosynthetics.co.za
🌍 Visit: www.geosynthetics.co.za
📍 Locations: South Africa | Ghana | Tanzania | Namibia | Ivory Coast | Mozambique and more