Hornsby Quarry Road Construction Spoil Management project

NorthConnex is a nine kilometre tunnel that will link the M1 Pacific Motorway at Wahroonga to the Hills M2 Motorway at West Pennant Hills. Roads and Maritime Services is proposing to handle, manage and beneficially reuse spoil from NorthConnex at Hornsby Quarry.

Hornsby Quarry is located west of Hornsby town centre and next to the Berowra Valley National Park.

About this project

NorthConnex is a nine kilometre tunnel that will link the M1 Pacific Motorway at Wahroonga to the Hills M2 Motorway at West Pennant Hills.

Construction of NorthConnex will produce around 2.6 million cubic metres of spoil. Hornsby Quarry was one of six sites identified in the NorthConnex Environmental Impact Statement (EIS) as having the necessary capacity to receive spoil material generated by the project.

Roads and Maritime Services is proposing to handle, manage and beneficially reuse up to one million cubic metres of clean spoil from NorthConnex at Hornsby Quarry – an environmentally sustainable use for the spoil.

This project would minimise the overall distance required for transporting the NorthConnex project spoil to various locations by around 3.7 million kilometres, which in turn would significantly reduce the potential impacts to the wider community and environment.

This project will cost around $31 million and is jointly funded by the NSW and Federal governments and the Hornsby Shire Council. The Lendlease Bouygues Joint Venture (LLBJV) is delivering the project.

Benefits

Partially filling the quarry with spoil from NorthConnex would:

  • Support Hornsby Shire Council's plan to rehabilitate the Hornsby Quarry site into a recreational facility for the local and regional community
  • Minimise the overall distances required for transporting the NorthConnex project spoil by around 3.7 million kilometres
  • Reduce the community's and Hornsby Shire Council's ongoing maintenance cost associated with quarry stabilisation.

Key features of the proposed work

The project will support Hornsby Shire Council's plan to rehabilitate the Hornsby Quarry site into a recreational facility for the local and regional community. The management and reuse of spoil from the construction of NorthConnex involves:

  • site establishment including:
    • assessing and monitoring quarry wall stability
    • dewatering the quarry void
    • closing and temporarily reconfiguring some of the existing Hornsby Mountain Bike Trail and walking tracks
    • clearing vegetation and establishing erosion and sediment controls
    • establishing a site compound, security fencing and signage around the works area
    • establishing noise mounds about five metres high around key sections of the stockpiling areas
    • widening and upgrading Bridge Road between the Hornsby TAFE and Roper Lane
    • Upgrading the existing access track from Bridge Road to Old Mans Valley
    • temporary closure of Roper Lane at its connection to Bridge Road
    • constructing a conveyor to transport spoil from the stockpiles to the quarry floor.
  • hauling spoil by truck from the NorthConnex spoil locations to the quarry
  • filling the quarry with spoil
    • discharging spoil from the conveyor on to a ‘telestacker’ to take the spoil from Old Mans Valley into the quarry pit floor
    • Spreading out the spoil on the quarry pit floor using a tunnel reclaimer and telestacker system
  • site demobilisation and rehabilitation:
    • taking apart and removing the compound and conveyer (apart from the foundations)
    • rehabilitating disturbed areas
    • removing security fencing and signage from the construction area and reinstating security fencing around the quarry
    • reinstating public access to areas outside the quarry exclusion zone including the mountain bike trails.

For more information view Hornsby Quarry on the NorthConnex site.

Indicative timeline

  • June 2016: Commencement of Bridge Road work
  • July 2016: Site establishment of Old Man’s Valley including establishment of five metre noise mounds
  • October 2016: Delivery of plant equipment to site for Old Man Valley and quarry bottom
  • April 2017: Bridge Road extension complete
  • April 2017: Conveyor delivery and installation
  • Mid 2017: Spoil haulage begins
  • Mid 2018: Quarry filling complete and site demobilisation begins
  • 2019: Site area returned to Hornsby Shire Council
Share this page: