Boral Cement Works Maldon
40 Maldon Bridge Road
Maldon NSW 2571
Boral's Maldon Operations, near Picton on the outer south-western edge of Sydney, play an important role in the company's NSW production and supply network.
First opened in 1949, the precinct includes the landmark Cement Works, a local concrete batching plant, and the aggregates rail transfer terminal which commenced operations in 2014.
With direct access to major road and rail corridors, the Maldon Operations offer Boral a strategic point from which to service building and construction needs in the greater Sydney area.
Construction of the Boral Maldon Rail Terminal began in September 2012, with the facility opening its gates in early 2014.
The Terminal will initially receive up to 1.75 million tonnes per annum of aggregates by rail from the Boral Peppertree Quarry at Marulan South.
From the Terminal, aggregates are despatched by truck to the Sydney market. There is also future potential for the Terminal to be used by other quarries in the Boral network.
Key processes include the release of aggregates from train wagons into the 'dump station', where they are transferred to the aggregate handling area by covered conveyors into various product bunkers.
From the bunkers, aggregate is loaded onto road trucks by front end loaders. Trucks are checked on the weighbridge prior to leaving the Terminal to ensure compliance with legal axle loads.
The approved hours of operation for site activities are as follows:
- Train unloading and stockpiling: Monday - Friday, 24 hours
- Truck loading and dispatch: Monday - Saturday, 5am - 10pm
- Maintenance: Monday - Sunday, 24 hours
Boral Maldon Rail Terminal
The Boral Maldon Rail Terminal is operated to the requirements of development consent 010.2010.00000921 .001, issued by Wollondilly Council on 20 July 2011.
Boral lodged the application with Council in December 2010 after a lengthy period of considering its requirements for the Terminal and the relevant planning legislation.
The application was also informed by a community consultation program, which incorporated a workshop of neighbours and other stakeholders held on 22 July 2010.
During the workshop, attendees were presented with a draft Environmental Impact Statement (EIS) which had been prepared to support the application.
A range of views were offered in response to the EIS, which in turn helped inform the final version of the document submitted to Council. You can view the summary of this feedback here.
The final EIS which formed part of the application is referred to through various parts of the Terminal's development consent.
An Operational Environment Management Plan (OEMP) has been developed as a condition of site's approval. The OEMP requires the endorsement of Wollondilly Shire Council.
The OEMP has been prepared for implementation on site and provides a system and procedures to address and manage potential environmental impacts associated with operations.
Applying the mitigation measures in the OEMP will ensure environmental commitments, reporting requirements, safeguards and mitigation measures specified in the Terminal's approval and relevant legislation are being adequately implemented, monitored and reviewed.
Sydney Aggregates Project
The greater Sydney metropolitan area has traditionally been the Australian building and construction sector's major market.
Boral is the leading producer and supplier of building and construction materials in the country. Accordingly, a significant amount of Sydney development, including many of the city’s best known structures, is underpinned by Boral-supplied concrete, cement and asphalt.
Concrete and asphalt are generated from hard rock aggregates. Since the 1800s, the majority of Sydney’s aggregate demand has been supplied from quarries at Emu Plains in western Sydney.
These quarries, including the Boral Emu Plains site, are nearing exhaustion of their hard rock resources.
Boral commenced planning for alternative sources of aggregate in the early 2000s to ensure the continuation of supply to its concrete, asphalt and other operations in Sydney.
The Boral Sydney Aggregates Project was the result of this planning. The Project involved the establishment of a new hard rock quarry at Marulan South, known as Peppertree, as well as the building of the Maldon Rail Terminal.
The Maldon Rail Terminal is integral to the Sydney Aggregates Project as all material quarried at Peppertree is shipped to the Sydney market via rail.
The Terminal, adjacent to the existing Boral Maldon Cement Works and Boral Maldon Concrete plant, sits alongside the Main Southern Railway. It also has ready road access to the Hume Highway via Picton Road.
Aggregate material arrives from Peppertree via train and is transferred to heavy vehicles, which in turn carries the material to locations throughout the Sydney metropolitan area.
Resources and Products
As a rail-to-road transfer terminal, the Boral Maldon Rail Terminal does not itself generate any products.
The main product passing through the terminal is hard rock aggregate produced at the Boral Peppertree Quarry, located in Marulan South.
The aggregate is made from the granodiorite resource upon which the quarry has been built. Granodiorite is an igneous rock similar to granite and is pale to medium grey in colour.
You can learn more about granodiorite and the aggregates which will be made from it by visiting the Boral Peppertree Quarry website.
Safety at Site
Boral has an ambition to deliver a safe and injury-free environment for all employees, contractors and visitors who may access sites.
During the 2011-12 financial year, Boral’s Lost Time Injury Frequency Rate (LTIFR) for employees and contractors reduced to 2.0 from 2.2 in the prior year.
It is our overarching strategy to continually reduce our LTIFR and percentage hours lost and in 2011 our LTIFR of 2.0 for employees and contractors combined represented a 19% improvement on the prior three year average.
Two critical projects have been implemented to assist Boral toward a 'zero incident' culture:
- the introduction of iCARE, an internally-developed, behaviourally-based safety improvement program;
- the 'One Boral' Safety Management System, which standardises safety management into a single whole-of-business system.
All Boral and contracting staff are inducted in order to raise awareness about the sites and construction hazards.
Authority to Work (AtW) and Safe Work Method Statements (SWMS) are developed, reviewed and approved prior to work being undertaken.
Audits are scheduled to ensure all activities are being undertaken correctly and safely.
The movement of materials is a critical part of Boral's business. As with many large organisations, the ability to transfer volumes of raw resources and finished products is essential to the company's success.
To meet its needs, Boral operates a significant fleet of heavy vehicles and is a customer of a range of haulage contractors across Australia.
Boral recognises the safety obligations accompanying the large scale use of heavy vehicles on public roads.
The business tries to ensure the highest standards of driving and vehicle maintenance are obtained to meet this objective.
We encourage all members of the community to give us feedback if they observe behaviour or incidents not aligning with this goal.
Specifics such as time, location, vehicle registration and colour help us to further investigate and take appropriate action.
For vehicles associated with the Boral Maldon Operations, you can send us your thoughts by phoning the site on 02 4640 0200.
The handling and movement of aggregate can be noisy and have the potential to impact on neighbouring properties.
The Noise Management Plan contained within the Terminal's OEMP has a range of mitigation measures to minimise any potential impacts.
These include conducting any noisy activities during daylight hours, ensuring vehicles are maintained to a high standard, undertaking operator and driver education programs and, if noisy activities are to occur, notifying residents and local businesses which may be impacted.
The handling and movement of aggregate at the Terminal has the potential to create dust.
It is our objective to ensure emissions from the Terminal are within air quality limits set by the NSW Environment Protection Authority (EPA) and that management practices are in place to minimise the potential for dust to leave the site.
The Air Quality Management Plan contained within the Terminal's OEMP includes a range of mitigation measures to minimise any potential impacts.
These include covering all loads leaving the site, ensuring vehicles are not overloaded, stabilising disturbed areas as soon as practicable with hydroseeding or some other form of cover, the application of water via tanker or fixed sprays, and enclosing conveyor systems.
Forecasts for winds or dry periods are also monitored. The operations are able to prepare for high wind situations with wetting of materials and the shutting down of particular operations as required.
There is also the possibility for sediment and other substances to be transported from the Terminal during storm events.
To manage these potential impacts, a series of sediment ponds have been installed to capture water and sediment before it discharges from site.
All stormwater drained from the Terminal operations is directed to these ponds.
The operation of the Terminal has generated an increase in traffic movements on the road and the associated need to manage potential traffic impacts.
It is our objective to minimise any disruption to local traffic, neighbouring businesses and residents.
For operations, all drivers regularly accessing the site are provided with safety awareness training. Regular reviews of the road users are undertaken.
Discontinued Clinker Manufacturing
During 2014, Boral announced the Maldon Cement Works kiln would no longer produce clinker after 31 December.
The decision was taken in response to several factors affecting the site and the Australian cement manufacturing industry as a whole.
The Maldon Works produced ‘off white’ clinker (which is ground to make cement) since the 1990s.
Market trends saw demand for ‘off white’ clinker decline as consumers turned toward ‘white’ clinker based products.
With prohibitively costly upgrades required for the kiln to enable ‘white’ clinker manufacturing, and an absence of a suitable supply of low-iron limestone, clinker production at Maldon became unsustainable.
While clinker production has ended, the site still operates with the grinding, packaging and logistics sections continuing.
‘White’ clinker is imported to the works for production of white cement products, while some ‘off white’ production can occur using blends of ‘white’ and ‘grey’ clinker.
The announcement did not affect the Boral Maldon Rail Terminal or Boral Maldon Concrete plant.
Local residents were informed that no change in operations would be discernible from outside the Cement Works as a result of the announcement.
You can read Boral’s media statement about the decision here.
Boral Maldon Cement Community Liaison Committee (CLC)
As a way of better sharing information and understanding matters of community interest, the Boral Maldon Cement Works runs a Community Liaison Committee (CLC).
The CLC meets twice a year at an independently chaired session which involves residents and local Boral employees. It examines the performance of the operations and allows attendees opportunity to raise any issues of concern.
The Boral Maldon Rail Terminal and Boral Maldon Concrete are also represented at the CLC meetings.
The next meeting of the CLC will be held on 26 November 2015. Participants must register before attending via 02 4640 0200.
Application for New Silos (Oct 2016)
We are currently preparing a development application (DA) seeking approval for the construction of two new storage silos in the grounds of our Maldon Cement Works. See the plans for the proposed new silos here.
The DA, which will be submitted to Wollondilly Shire Council for assessment, will include:
the construction of a new 60 tonne silo for cement, and a new 100 tonne silo for blended lime and 'slag'; and
a request for permission to dispatch up to 30000 tonnes of the blended product each year via road tanker.
During 2008, we received approval to build a plant through which we could blend lime and 'slag', a by-product of steel manufacturing.
At the time, the intent was to supply blended products for particular customers using rail transport.
Recently there has been growing demand for the blended products from major road projects. As most of these are not located near rail, we need to opt for delivery by road.
The new silos are therefore required so that the products can be held in bulk storage for later distribution across Sydney and southern NSW.
The proposed silos are smaller and lower than existing adjoining silos at the site. They are therefore very unlikely to change the existing appearance of the Cement Works.
The proposed distribution of up to 30000 tonnes of the blended products per year equates to an additional two to three tankers per day between 5am and 4pm.
This small number will have a negligible impact on the Maldon Bridge-Picton Roads intersection and adjacent level crossing.
Apart from minor noise and localised dust during construction of the silos (once approved), there will be no difference to present operations.
All of the site's current mitigation measures and environmental obligations will remain in place.