For immediate release, 15 July 2025, Sydney: Boral Limited (“Boral”) welcomed the official opening of the Western Harbour Tunnel precasting facility at Emu Plains this week by NSW Premier, the Hon. Chris Minns MP and NSW Minister for Roads and Regional Transport, the Hon. Jenny Aitchison MP, which continues the historic site’s proud tradition of helping build Sydney.
Boral has leased 18 hectares of its Emu Plains site to Acciona, a global renewable energy and infrastructure solutions provider, to establish the precast facility adjacent a purpose-built concrete batching plant. This will supply approximately 90,000m3 of concrete to manufacture precast segments and culverts for Western Harbour Tunnel. The tunnel will connect the Rozelle Interchange to the Warringah Freeway near North Sydney, crossing underneath Sydney Harbour between Birchgrove and Waverton.
Boral CEO and Managing Director Vik Bansal, said: “The establishment of a precast facility at our Emu Plains site – a former quarry and now recycling operation – continues its proud history of providing construction materials to landmark infrastructure projects in the Sydney region.”
“It is also proof of our ability to recycle assets,” Mr Bansal said.
“During its life as a quarry, between 1883 and 2014, Emu Plains has supported Sydney’s housing and infrastructure projects for generations.
“Emu Plains has directly supplied construction materials to iconic projects including the Sydney Harbour Bridge, Warragamba Dam and Sydney Olympic Park.”
Boral will operate a wet mix concrete batch plant, capable of producing up to 120m3 of concrete per hour, adjacent the precast facility. This will supply concrete for the precast facility to make more than 13,000 concrete segments and nearly 1,400 culverts for Western Harbour Tunnel.
Boral’s Executive General Manager NSW Concrete and Quarries Mark Campbell said a wet mix plant allows for concrete ingredients to be mixed within the plant with the wet concrete then transferred directly into precast tunnel segment moulds.
“The concrete plant was made in Queensland and then transported via truck to the site where it was erected and recently commissioned,” Mr Campbell said. “The plant utilises raw materials from our integrated upstream quarry operations at Peppertree and Dunmore, along with cement manufactured from our Berrima plant.”
Boral continues to operate at Emu Plains with its recycling operations at site, alongside the precast facility.
Boral’s Emu Plains Recycling Operations include the processing and blending of quarry materials stored on site and the receipt of virgin excavated natural materials (VENM), which are sorted, processed and blended to produce a range of aggregates, sands and engineered fill products that are dispatched across the Sydney market.
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About Boral
Boral is the largest vertically-integrated construction materials company in Australia.
Our network includes prized quarry and cement infrastructure, bitumen, construction materials recycling, asphalt and concrete batching operations.
We employ about 7,500 employees and contractors across our operations that span more than 360 sites nation-wide.
For more than 75 years we’ve been building something great in Australia - rarely a day goes by that you wouldn’t pass one of our sites or trucks, enter a building, use a road, bridge, tunnel, footpath or other critical infrastructure that our people and products have helped enable.
