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.

Updates and announcements

An Environmental Impact Statement (EIS) was prepared for the proposed Hornsby Quarry Road Construction Spoil Management Project that identified and assessed the potential environmental and social impacts of the project and outlined management measures.

The EIS was on public display from 5 August 2015 to 4 September 2015. A total of 47 submissions were received. The final submissions report was submitted to DPE for review and approval by the NSW Minister for Planning.

The Minister for Planning approved the Hornsby Quarry Construction Spoil Management Project on 18 January 2016.

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 would cost around $31 million and would be jointly funded by the NSW and Federal governments and the Hornsby Shire Council. The Lendlease Bouygues Joint Venture (LLBJV) would deliver the project.

Indicative cross section of Hornsby Quarry showing the relative elevations of the different areas within the site - click for a larger version

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 would 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 would involve:

  • 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 of Bridge Road between the Hornsby TAFE and Roper Lane
    • Sealing 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
  • Stockpiling the spoil by dozers in Old Mans Valley
  • Filling the quarry with spoil:
    • A front end loader will place the spoil from the stockpiles onto conveyer
    • Placing spoil in the quarry void using a conveyor
    • Excavators and trucks will move the spoil along the quarry floor and a dozer will spread the material. Rollers will be used to compact the material
  • 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.

Next steps

Indicative timeline

  • June 2016: Start Bridge Road work
  • July 2016: Site establishment Old Mans Valley including the establishment of five metre noise mounds
  • October 2016: Delivery of plant equipment to site for Old Man Valley and quarry bottom
  • January 2017: Start of spoil haulage for up to 15 months duration
  • End 2018: Complete quarry filling and site demobilisation.
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