Boral Maldon Operations
Boral's Maldon Operations, near Picton on the south-western outskirts of the greater Sydney region, act as an important hub for the supply of building and construction materials into the metropolitan area.
They consist of the landmark Cement Works, a Concrete batching plant, and a Rail Terminal operated by Boral Quarries NSW/ACT.
Please note these sites are not open to the public. All sales and product enquiries may only be directed to 02 9033 4000 (Cement), 1300 552 555 (Concrete) or 1300 723 999 (Quarries), or you can send an online request.
Maldon Bridge Road
Maldon NSW 2571
About the Boral Maldon Operations
Boral's three operations at Maldon, located outside Picton in the Wollondilly region of NSW, form a strategic hub for the supply of crucial building and construction materials into the neighbouring greater Sydney metropolitan area.
The operations began with the opening of the Cement Works in April 1951 as a response to the post-World War II building and construction boom.
With direct road (Hume Highway) and rail (Main Southern Railway) access into Sydney, the site has continuously supplied bulk and bagged cement since that time.
Up until 2014, the Cement Works hosted three different kilns on-site. The kilns were used to manufacture clinker, the precursor material to 'powdered' cement as bought in hardware stores.
Since the decommissioning of Kiln 3 at the end of that year, the Cement Works has reverted to grinding clinker from the Boral Berrima Cement Works and imported material in its mill.
With the kiln no longer in service the associated stack, a local landmark, was demolished during 2018.
Over its life, the site has produced and ground 'grey', 'white' and 'off white' variants of clinker. Grey clinker is now the predominant form used at Maldon.
The Cement Works hosts a modern bagging facility to support dispatch of bagged cement products around the state. The facility incorporates advanced technology and robotics to assist with the speed and efficiency of supply.
Bulk cement is dispatched by trains and road tankers, both familiar sights around Maldon. During 2018, the Cement Works began using isotainers - a tube-like vessel set in a rectangular frame which can carry as much cement as a road tanker.
Travelling south along Maldon Bridge Road, the next of Boral's local operations is the Quarries Rail Terminal.
The Terminal was opened in 2014 as part of the greater Sydney Aggregates Project which also saw the establishment of the Boral Peppertree Quarry at Marulan South.
The Project sought to initiate new a hard rock resource replacement for the now closed quarries at Emu Plains in western Sydney, which had served metropolitan building needs since the 1800s.
The main role of the Terminal is to receive trains carrying the hard rock aggregates produced at Peppertree.
From Maldon, the aggregates are dispatched by road using truck-and-dog or tipper combinations to customers across Sydney, including Boral's own concrete and asphalt plants.
Today the site supports eight employees who are based at the Terminal, and seven Boral Logistics drivers are also attached to the facility.
The most southerly operation is the Concrete plant. The plant, originally established in the 1980s, is one of 11 making up Boral's Illawarra/Southern Highlands concrete network.
The site produces pre-mixed concrete products which are sent via agitators ('concrete mixers' or 'cement trucks') to customer worksites around the network region and into south-west and western Sydney.
Aggregates delivered through the Rail Terminal and cement produced at the Cement Works are used at the concrete plant to generate the site's products.
Maldon Rail Terminal: Blending Plant Proposal (Jul 2020)
We're currently working on a plan to broaden the Rail Terminal's offerings to builders and construction firms across the region by introducing a blending plant at the site.
A blending plant allows the production of materials, such as stronger roadbases, to specifications being increasingly required by customers such as Transport for NSW.
Blended products find their way into the concrete and asphalt used in everything from major roads and bridges through to public and private buildings such as hospitals, schools and residential homes.
The proposed plant, to be located entirely within the Rail Terminal's existing operations, will feature a pugmill, coating plant, bins, conveyors and a silo.
The pugmill is where the actual blending occurs. It will take in aggregates (from the Boral Peppertree Quarry), cement from the neighbouring Cement Works, and water to create the end products.
The coating plant can be used to coat aggregates with precoat oil, allowing the products to be ready for use in road surfacing.
The proposal requires the approval of Wollondilly Council and so we're preparing an application for their assessment. We're hoping to submit this during July.
We'll seek approval to blend up to 250 000 tonnes of products each year. This is something we'll be able to do within our existing operating hours and environmental obligations, so no other on-site changes are required.
With new products, however, comes the possibility we'll need to move more material. Accordingly, our application will include a request for a relatively small increase in the number of heavy vehicles travelling to and from the site each day.
We'll be asking for the current maximum limit on these movements to be increased by up to 56 trucks per operating day. This equates to just over three for every hour the Terminal is currently allowed to be open - a limited number when compared to heavy vehicle traffic already using the precinct.
As we move into the formal planning assessment, we'd like to hear any feedback or answer any questions our neighbours and community might have about these plans.
You can get in touch by sending us an email, or by calling our Stakeholder Relations Manager (based at Maldon) on 0401 894 097.
With approval granted and everything else going smoothly, we're hopeful we will be able to have the new blending plant operating by mid 2021.
General Approvals: Maldon Rail Terminal & Maldon Concrete
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, and its supporting Environmental Impact Statement (EIS).
The consent sets out the operating, environmental and reporting conditions the Terminal must comply with throughout its operational life.
A modification to this consent is currently being prepared to allow a blending plant to be established at the site - see the Maldon Rail Terminal: Blending Plant Proposal (Jul 2020) tab.
Boral Maldon Concrete is operated according to existing use rights which were confirmed by Council during 1985.
To find out more about how Boral operates its cement facilities like the Boral Maldon Cement Works, visit our About Cement page.
To find out more about how Boral operates its concrete plants, like Boral Maldon Concrete, visit our About Concrete page.
Activity occurs around the Boral Maldon Operations on a 24 hour-seven day basis.
This takes place mainly at the Cement Works as the Boral Maldon Rail Terminal has some restrictions included in its planning consent.
The Concrete site normally only operates during what can be considered regular business hours.
The Terminal receives up to 1.75 million tonnes per annum of aggregates by rail from the Boral Peppertree Quarry at Marulan South.
Key processes include the release of aggregates from train wagons into the 'dump station', from 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 Rail Terminal to ensure compliance with legal axle loads.
The Rail Terminal's approved hours of operation for site activities are:
- Train unloading and stockpiling: Monday - Friday, 24 hours
- Truck loading and dispatch: Monday - Saturday, 5am - 10pm
- Maintenance: Monday - Sunday, 24 hours
Environmental Management: Maldon Rail Terminal
Following its approval in 2011 and subsequent opening during 2014, an Operational Environmental Management Plan (OEMP) was developed for the Boral Maldon Rail Terminal.
The OEMP guides the site, sets benchmarks and assists with managing the operations in respect to a number of relevant environmental factors. The original version was submitted to and approved by Wollondilly Council.
Some of the aspects covered by the OEMP include the management of air quality and noise. You can read more about the initiatives we have in place in relation to these topics below.
The handling and movement of aggregate at the Rail Terminal has the potential to create dust.
It is our objective to ensure any emissions from the Rail Terminal are within air quality limits set by the NSW Environment Protection Authority (EPA), and that practices are in place to minimise the potential for dust to leave the site.
The OEMP includes an Air Quality Management Plan with a range of mitigation measures to assist with this aim.
These include covering of all loads leaving the site, ensuring vehicles are not overloaded, stabilising disturbed areas with hydroseeding or some other form of cover, the application of water via water cart or fixed sprays, and enclosed 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 activities as required.
The handling and movement of aggregate can also be noisy and have the potential to affect neighbouring properties.
As an example, trains bringing aggregate to the Rail Terminal arrive and are unloaded in the early hours of the morning.
The OEMP also contains a Noise Management Plan. Mitigation measures 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 which may be affected.
Since September 2004, the Boral Maldon Cement Works has organised regular community meetings attended by neighbours, representatives of Wollondilly Council and other local community groups.
The sessions afford an opportunity to review the performance of the operations, and allows attendees to raise any issues of concern.
The meeting also cover the activities of both the Boral Maldon Rail Terminal and Boral Maldon Concrete.
Currently meetings are held annually. You can view the presentations and notes taken from the past three years below. If you'd like information from earlier meetings, you can send us a request.
- Boral Maldon Cement Community Meeting - Notes (Nov 2018)
- Boral Maldon Cement Community Meeting - Presentation (Nov 2018)
Newsletters issued from the Boral Maldon Operations during the last three years can be viewed below. If you'd like access to older information, please send us an email.