Colorado Gold Mine Pond Liner Replacement Highlights COMANCO’s Mining Containment Expertise

Rain, lightning, wind, standing water, and high-altitude conditions challenged COMANCO crews during a recent pond liner replacement at a Colorado gold mine. Despite changing conditions throughout September, the team successfully removed more than 215,000 SF of aging geomembrane and installed 200,000 SF of new HDPE liner to restore the facility’s primary containment system. At a high-altitude gold mine in Colorado, progress depended on recognizing which tasks conditions would safely allow.

COMANCO removed the aging top geomembrane layer from an emergency overflow pond and installed a new primary containment liner. The project began in early September and wrapped up with a final walkthrough at the end of the month.

Along the way, the crew balanced demolition, installation, dewatering support, and detailed quality control work.

UV exposure had degraded the primary geomembrane layer in the Colorado gold mine’s emergency overflow pond, requiring replacement.

The scope included demolishing and disposing of 215,000 SF of the existing liner. COMANCO then installed 200,000 SF of AGRU 80-mil double-sided textured HDPE geomembrane. The textured HDPE geomembrane was selected to provide the containment performance and interface friction characteristics required for the pond’s operating conditions and slopes.

This work restored the pond’s primary containment liner to support the facility’s containment requirements. Emergency overflow ponds play an important role in mining containment systems by providing additional storage capacity during storm events, operational upsets, or other unexpected inflows. These facilities help mines maintain controlled containment, support environmental compliance, and protect surrounding soil and groundwater by ensuring liquids remain within the engineered system. COMANCO has supported the construction, repair, and maintenance of mining containment ponds throughout the western United States, helping operators maintain reliable containment infrastructure.

During demolition, the crew used a winch to help remove the existing geomembrane. This approach helped reduce manual handling risks while supporting controlled liner removal.

However, removing the old material was only one part of the assignment. Difficult slope work, increased quantities, and detailed tie-ins also required close coordination throughout construction. Mining pond rehabilitation projects often present unique challenges because replacement work must occur within existing containment facilities while maintaining safety, environmental compliance, and coordination with ongoing site operations. COMANCO’s experience with mining containment systems helped the team adapt its approach as conditions evolved throughout the project.

Weather repeatedly affected the work sequence. Rain brought water accumulation, while lightning and wind added further constraints.

As conditions changed, the crew shifted among liner deployment, welding, geogrid and zip-tie work, and dewatering assistance. Quality control, detail work, and cleanup also formed part of that changing sequence.

Rather than relying on one fixed activity, the team adjusted its daily priorities around site conditions and safety requirements.

Repeated dewatering needs added another layer of coordination. The crew assisted with those efforts while managing the remaining installation activities.

The project’s high altitude also required time for acclimation. Together, these conditions made adaptability essential to the field effort. Adapting to changing field conditions is a common requirement on mining containment projects. COMANCO’s mining crews routinely work in active mine environments where weather, terrain, safety requirements, and operational schedules can influence daily activities. Drawing on experience with pond liner installations, heap leach facilities, containment repairs, and ongoing maintenance work, the team was able to shift resources, adjust work sequencing, and continue making progress while maintaining safety and quality standards.

In mining environments, weather-related interruptions can affect geomembrane deployment, seam welding, material handling, and quality-control activities. By continuously evaluating site conditions, the crew identified productive work that could be performed safely while protecting the integrity of the installation.

The MSHA-regulated site required mine-specific safety training before work began. Throughout the project, the team conducted daily safety meetings and hazard reviews.

Job safety analyses guided task planning, and the team followed hot-work permit requirements where applicable.

As the work sequence changed, those requirements remained part of the daily routine. The crew continued addressing slope work, welding, tie-ins, and quality control details throughout the installation.

Field personnel, QA/QC personnel, and project management coordinated their efforts as actual conditions affected the work. That collaboration helped the team stay focused through weather interruptions and changing field needs.

Field Manager James Kile, Superintendent Martin Calderon Sr., and Leadman Esteban Solano supported field execution. Project Manager Michael Taylor and Project Engineer Jose Martinez supported project coordination.

The crew’s contribution extended across the full scope. Team members moved between demolition, deployment, welding, detail work, quality control, and cleanup as conditions changed.

With the pond liner replacement complete, the customer praised the crew’s work: