Boral Maldon Operations
Boral's operations at Maldon, near Picton on the south-western outskirts of the greater Sydney region, consist of a landmark cement works, a concrete batching plant, and a rail terminal operated by Boral Quarries NSW/ACT.
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 an 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 local, Macarthur, greater Sydney, Illawarra and Southern Highlands areas.
About the Maldon Rail Terminal
The greater Sydney metropolitan area has traditionally been the Australian building and construction sector's major market. A significant amount of Sydney development, including many of the city’s best known structures, is underpinned by Boral-supplied concrete, cement, asphalt and other products.
Concrete and asphalt production relies on hard rock aggregates. From the 1800s, the majority of Sydney’s aggregate demand was supplied from now closed quarries at Emu Plains in western Sydney. Seeing that these quarries were nearing the end of their lifespan, Boral commenced planning for alternative sources of aggregate in the early 2000s to ensure the continuation of supply. A project, the Sydney Aggregates Project, resulted from this planning.
The Project involved the establishment of a new hard rock quarry at Marulan South (the Peppertree Quarry), as well as the building of the Terminal. The Terminal is integral to the objective of the Project as all material quarried at Peppertree is shipped to the Sydney market via rail to Maldon.
The Terminal, adjacent to the long-standing Maldon Cement Works and 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 carry the material to locations throughout the Sydney metropolitan and surrounding areas.
Maldon Rail Terminal - Changes to Rail Movements (Nov 2018)
The Maldon Rail Terminal forms a key link in the chain which supplies building and construction materials to the Sydney market. The Terminal was built to receive trains loaded with hard rock aggregates, the core 'ingredient' of essential building materials such as concrete and asphalt.
Managing the movement of materials (also received from our quarries at Dunmore near Kiama, and Peats Ridge on the Central Coast) through the three terminals is like a huge, ongoing game of chess. Apart from ensuring space is available at the sites to take the aggregates, each terminal must carefully coordinate the arrival and departure of trains with the availability of rail ‘pathways’, or empty slots on the rail lines, as controlled by the rail operators.
Trains aren’t able to overtake each other like vehicles on the road. Accordingly, demand for rail pathways amongst freight and passenger rail users in NSW is always at a premium. The balancing act between obtaining rail pathways when they become available, and meeting customer needs in a timely fashion, means we’ve been looking at being more flexible on how we move our trains.
Since Maldon Terminal opened in 2014, a typical day will see two trains arrive and depart in the early-to-mid morning and early-to-mid evening. However, our planning approval allows for 24 hour acceptance and unloading of trains at the Terminal.
As a result, from 2 December 2018 we’ve decided to begin accepting train arrivals in the early morning hours. While times will be influenced by the pathways made available to us by rail operators, we’re expecting trains will normally arrive at Maldon around 1-2am.
Although we don’t expect these new arrangements to be noticeable from outside our boundaries, we’re very keen to hear from any neighbours should attention be drawn by any new sights, sounds or similar. You can call the Terminal on 4677 2946, or send an email to raise issues or make comments. As always, your feedback will greatly help us to manage this transition.
Operations - Maldon Rail Terminal
Construction of the Boral Maldon Rail Terminal began in September 2012, with the facility opening its gates in early 2014.
The Terminal receives 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 dispatched by truck to customers across the greater Sydney metropolitan area and surrounds.
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
Planning Approvals - Maldon Rail Terminal
The Terminal is operated to the requirements of development consent 010.2010.00000921.001, issued by Wollondilly Council on 20 July 2011.
The consent is supported by an Environmental Impact Statement (EIS), prepared to support the application. The EIS is referred to through various parts of the Terminal's development consent.
An Operational Environment Management Plan (OEMP) was also developed as a condition of site's approval and endorsed by Council. The OEMP provides a system and procedures to address and manage potential environmental impacts associated with operations.
The mitigation measures included in the OEMP ensure environmental commitments, reporting requirements, safeguards and mitigation measures specified in the Terminal's approval and relevant legislation are adequately implemented, monitored and reviewed.
Resources and Products - Maldon Rail Terminal
As a rail-to-road transfer terminal, the Maldon Rail Terminal does not itself generate any products. The main product passing through the Terminal is hard rock aggregate produced at the Peppertree Quarry, located in Marulan South.
The aggregate is made from the granodiorite resource upon which the quarry is positioned. Granodiorite is an igneous rock similar to granite and is pale to medium grey in colour.
Transport and Traffic Management - Maldon Rail Terminal
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 by road and rail is essential to the company's success.
Boral recognises the safety obligations accompanying the large scale use of heavy vehicles on public roads. Training is conducted for contractors and drivers accessing the sites, and ongoing communication had with road users to ensure they are aware of Boral-related traffic movements and contacts for any related issues.
We encourage all members of the community to provide feedback if they observe behaviour not aligning with our safety goals. Specifics such as time, location, vehicle registration and colour help us to further investigate and take appropriate action. To report any inappropriate conduct, you can send us an email.
Noise - Maldon Rail Terminal
The handling and movement of aggregate can be noisy and have the potential to impact on neighbouring properties. From December 2018, trains bringing aggregate to the Terminal will also commence arriving and being unloaded in the early hours of the morning.
A Noise Management Plan contained within the Terminal's OEMP includes a range of mitigation measures to minimise any potential impacts.
These include ensuring vehicles and train stock 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 affected.
Air Quality - Maldon Rail Terminal
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 effects. These include the covering of 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.
Community Meetings - Maldon Cement
As a way of better sharing information and understanding matters of community interest, Maldon Cement holds annual community meetings. The sessions are independently chaired and attended by residents, representatives of Council, and members of Boral's three local operations teams. The performance of the operations are reviewed through the meetings which allows attendees opportunity to raise any issues of concern.
Meetings are typically held in November of each year. You can review the presentations and notes taken from the past three years' of meetings below. If you'd like information from earlier meetings, you can send us a request.
- Meeting notes - Maldon Cement Community Meeting November 2018
- Presentation - Maldon Cement Community Meeting November 2018
- Meeting notes - Maldon Cement Community Meeting November 2017
- Presentation - Maldon Cement Community Meeting November 2017