Civil Works Updates
August 2024 – October 2024
From August to October 2024 significant progress continued to be made across the site, with key elements being completed. All concrete road pavements on site were completed with the final section of the RL90 Road, western end completed in August. Watch the final concrete pour of the road barrier, in the August Drone Video.
All retaining walls including precast, cast in-situ and gabion basket walls have been finished with the final gabion baskets being placed along the Northern Access Track. See the gabions being filled in the August Drone Video.
As the earthworks batters are finalised across the site, hydromulching is applied.
The hydromulching mixture contains wood fibre, mulch, fertiliser, seed, water, and a bright green non-toxic dye.
Hydromulching encourages quick seed germination across large open areas. It does this by locking down the topsoil by forming a protective cover and allowing the seeds to take root, germinate and grow to full height.
This vegetation binds together the soil to prevent erosion especially on steep slopes.
See if you can spot the areas sprayed green during hydromulching in the September Drone Video.
Works on the installation of major trunk drainage structures including pits and pipes are progressing.
In the October Drone footage, see the new pipes heading across Old Mans Valley and progress with the works at the Crusher Plant.
Images (top to bottom): Finished concrete pavement on western end of RL90 Road; Filling the final gabion baskets along Northern Access Track; Hydromulching of Old Mans Valley Batters.
Videos: Drone footage August, September and October.
May 2024 – July 2024
Over the cooler months of May through July, solid progress has continued, despite regular periods of wet weather, including Sydney recording thirteen straight days with 3mm of rainfall or more at the start of May. This record was just short of the all-time record of sixteen days straight in 2022 and 1943. The project has been extended by 186 days due inclement weather since the project started in September 2021.
The proximity of Hornsby Park and the former quarry site to the Hornsby Town Centre adds to the value of this hidden gem. The site is perfectly located barely half a kilometre away from Hornsby Station, a major public transport node. Start to appreciate just how close the site is to Hornsby Town Centre in the May 2024 drone video, as we take flight from the Hornsby Aquatic and Leisure Centre and head over the site.
Check out progress on site in our May and July 2024 drone videos, including the reshaped Old Mans Valley platform, Quarry void including the new lake area and Crusher Plant area.
Images (top to bottom): Aerial view of Hornsby Park and former Quarry from the Hornsby Aquatic and Leisure Centre. Taken 21 May 2024; Locality Sketch of quarry site and surrounding land uses; Aerial view across the former Quarry and Old Mans Valley towards Hornsby Town Centre. Taken 21 May 2024.
Videos: Drone footage May and July.
February 2024 – April 2024
The focus during February to April 2024 has remained on the construction of the retaining wall structures around the quarry void. In particular, the walls on the eastern and north-western edge of the Quarry Void.
A significant milestone was achieved in February with the placement of the final precast panel wall section for the project.
A 350 Tonne crane was used to lift the panels into place. The crane needed a maximum lift radius of 48m, and seven semi-trailer loads of counterweights. The largest precast panel was 4.65m tall and over 9 Tonnes in weight.
Watch the video clip as the final panel is lifted into place.
Progress is also being made on the concrete pavement access roads.
To see what else is happening on site check out the video taken on 18 March 2024
Images (top to bottom): 350 Tonne crane ready for lifting the precast wall panels into place; Precast wall panels positioned on foundation slabs; Counterweights on crane; Securing the final precast wall panel ready for lift; Final precast wall panel being lifted into place; View of completed placement of precast wall panels; Steel reinforcement placement for concrete pavement; Workers finishing concrete pavement pour.
Videos: Lifting the final precast wall panel into place; Drone flight over the site 18 March 2024.
December 2023 – January 2024
As 2023 ends and 2024 begins, anticipation is growing as the various improvements across the site start coming together to reveal the final stabilised landform. Continued progress across all key milestones has the project on track for completion this year. The worksite was closed for the Christmas/New Year break from 22 December to 8 January 2024.
During December and January resources have been focused on three key areas.
- The final section of the drainage works with the completion of the open channel section.
- The first section of concrete pavement along the Northern Access Track (NAT).
- The retaining wall adjacent to the access road on the eastern edge of the Quarry Void. Due to its length, approximately 120m and height, over five metres in parts, the wall it is being constructed in eight sections.
Get a bird’s eye view of the transformation taking place across the site in the video taken on 1 Feb 2024.
Images (top to bottom): Finished section of open drainage channel; Preparation works for installation of the coarse trash rack; Coarse track rack (posts) installed, and channel works complete; Placing mesh for concrete pavement works on NAT; First pavement section completed on NAT; Construction of Section 7 of Retaining Wall; Retaining Wall – Section 4 underway and section 5 complete.
Video: Drone flight over the site 1 February 2024.
October/November 2023
Works across the site have progressed well in October/November.
As part of the stabilisation stage of the project several retaining walls and barriers are being constructed. The purpose of these walls is to ensure safety for park users by providing edge protection from the sheer quarry faces and retaining the surrounding embankments and access roads.
Different construction methods have been employed for these walls.
Precast concrete panels have been used for speed of installation and safety of workers on the edge of the quarry faces, the largest of these panels being over 3m in height. Placing these panels on the edge of a cliff face requires precision and a very large crane.
Other concrete walls will be built onsite which involves constructing formwork, fixing steel reinforcement, and pouring concrete. During October/November works have commenced on a large retaining wall above the eastern quarry face.
Retaining walls across the Northern Mound have been completed using gabion baskets. These have been built by filling wire baskets with dark grey basalt quarry rock, in keeping with the natural rock at the quarry.
Images (top to bottom): Precast concrete wall panels; Crane used for unloading precast panels; Large crane lifting precast panels into place on quarry cliff face; Workers filling gabion baskets; Gabion basket retaining wall; Close up of basalt rock in wire baskets; View of gabion basket retaining walls; Formwork and reinforcement in place for footing of concrete wall; Pouring concrete footing.
August/September 2023
Further progress has been made across the site following dry conditions in August/September.
September 2023 marks two years since the contractor began work onsite.
Key to having a functional site in the future is having safe access to all areas which will be designated as public space.
The road known as the Southern Access Track will be one of these important links around the site.
This road sits above the highest quarry face on the site and previously the size of vehicle using the track was quite limited.
Significant work was required to ensure that the road is protected from future erosion and can support the necessary pavement.
Long micropiles were installed deep into the ground to anchor and strengthen the road. The micropiles were then encased in concrete to form a beam on which the road pavement could be built and tied into.
As part of the works some of the road uphill slope was cut back to improve stability.
During August and September, this area was completed with the pouring of the concrete barrier and road pavement.
This will now allow safe access to this part of the site.
Images (top to bottom): Micropiles being installed. August 2022; Micropiles installed. August 2022; Micropiling capping beam being formed. Jan 2023; Finished capping beam. Jan 2023; Reinforcement and formwork for road pavement and road barrier. Aug 2023; Pouring concrete pavement. Aug 2023; Finished section of Southern Access Track. Sept 2023; Finished section of Southern Access Track and cut back slope above. Sept 2023
June/July 2023
Good progress has been made across the site following mostly dry conditions in June and July.
The project has been extended by 164 days due inclement weather since the project started in September 2021.
In order to ensure a safe environment for the future parkland it is critical to ensure that the former quarry walls are secured and stabilised. These stabilisation works have involved the installation of rock bolts and rockfall mesh across the walls and provision of minor rock fall catch fencing. These works together with regrading some excessively steep earth slopes will provide a safe space for future park embellishments.
Images (top to bottom): Workers draping and attaching rockfall mesh; Rock bolting drilling rig; Draping and fixing rockfall mesh; Quarry face covered in mesh; Close-up of mesh; Rock fall catch fence at crest of quarry wall; Finished covered face with mesh and rock bolts.
April/May 2023
Good progress has been made across the site following mostly dry conditions in May. Progress in April was impacted by the public holidays for Easter and Anzac Day and inclement weather.
There has been sustained progress on the construction of the drainage network across the site. Works have included the installation of stormwater drainage pipes along the Northern Access Track and construction of major drainage structures such as inlet structures, track racks and headwalls.
Earthworks to reshape the land to its future form have continued in the Quarry Void and Old Mans Valley including some rock excavation works at the southern end of Old Mans Valley to create a future carpark.
Images (top to bottom): Laying stormwater pipes; Construction of inlet structure; Construction of a coarse trash rack, headwall and Inlet structure; Construction of headwall; Earthworks in the Quarry Void; Dozer reshaping material in the Quarry Void; Excavation in Old Mans Valley for future carparking.
February/March 2023
During February, the site was impacted by intense storms almost weekly. In one event, the site recorded over 30mm of rain within six minutes. These storms delayed the planned works and caused damage to existing works. With such severe rainfall events likely to continue impacting the site, it reinforces the need to provide significant drainage infrastructure within the site to deal with the large catchment of stormwater that enters the site from the adjoining areas.
During this period, there has been continued progress with the major trunk drainage works with Basin 1 & 2 now completed and the majority of the Reinforced Concrete Box Culverts now installed. Once completed, the trunk drainage system will transport stormwater through the site without causing damage to the adjacent environment and assets.
Other works have included continued earthworks on the main platforms in Old Mans Valley.
Images (top to bottom): Site awash after February Storm, Construction of Basin 1 – Trunk Drainage Line and Bulk earthworks in Old Mans Valley.
December 2022/January 2023
December saw good progress across the site due to a very welcome spell of fine weather. The site was closed over the Christmas / New Year period with work resuming on 9 January 2023.
However, the site was once again impacted by more heavy deluges. This again hampered works, slowing progress in January.
Works have included bulk earthworks across the site, further placement and backfilling of box culverts for the Old Mans Valley Drainage Diversion and topsoiling on the Northern Spoil Mound.
Images (top to bottom): Backfilling culverts – Old Mans Valley Drainage Diversion, Northern Spoil Mound
October/November 2022
October saw further rain events continue to impact progress across the site. Topsoiling works progressed with an additional drain required to redirect water seepage. In the quarry void, filling continued during dry periods and there was work to remove loose rock which will be used in the retaining wall material.
There was good progress across the site in November due to a very welcome spell of fine weather. Works included the placement of box culverts for the Old Mans Valley Drainage Diversion, topsoiling and earthworks on the Northern Spoil Mound.
The current date for Practical Completion is February 2024. This includes a delay of 304 days due to wet weather-related issues, supply chain issues and scope changes.
Images (top to bottom): Top Soiling – Northern Spoil Mound – November 2022, Culvert installation – November 2022
August/September 2022 – Unfavourable weather hampers progress
At the end of August the Bureau of Meteorology (BOM) confirmed that Sydney is on track for its wettest year ever after passing 2-metre milestone for only the fifth time.
The works underway at Hornsby Park are focussed on moving huge quantities of earth around to make the site safe and to create the platforms for future use. When the soil becomes saturated, or underwater, work is impossible. This year we have already lost almost 120 working days as a result of wet weather. On 13 September the BOM officially declared that Australia’s east coast was experiencing the third La Niña weather system in a row, increasing the risk of rain and flooding in the coming months (ABC News).
While every effort is being made to reduce the impacts of the weather through enhanced drainage solutions, until these are in place the site will continue to be inundated in major weather events.
We will continue to provide updates as to how this will impact timelines for the project while hoping that perhaps the BOM’s predictions won’t be so bad after all.
Pictures show how the Quarry Void has been flooded on two occasions this year, between which we’d just managed to get back to working on site, only to be delayed again.
Images (top to bottom): Site conditions – July 2022, Hornsby Quarry Void – 8 July 2022, Hornsby Quarry Void – 30 June 2022, April 2022
February/March 2022 – Works delayed
During February and March 2022, Hornsby Shire local government area, including the Hornsby Quarry site experienced significant rainfall.
The rainfall over a one month period was 830mm which is over 70 percent of the annual average rainfall for Hornsby. The programmed works have been impacted as a result of this rainfall.
November 2021 – Notification of tree clearing
Bulk earthworks have commenced on the Hornsby Park site. The earthworks are necessary to re-shape and stabilise the site to make the park safe. As part of these works, the removal of some trees and vegetation is necessary.
These works will be carried out in line with the approved Vegetation Management Plan.
Work hours will be limited to those in the table below, to minimise noise and disruption to residents. Noise levels will be monitored throughout the project.
Temporary closure of mountain bike trails
Due to the earthworks, some mountain bike trails will need to be temporarily closed. Most of these trails should re-open within a week or two of their closure. The trails affected will be Lava Flow, Turkey Run and Jump Park.
Details on which sections will be closed, when and for how long will be updated regularly on our Hornsby Park MBT twitter feed https://twitter.com/HornsbyMBT.
November 2021 – Hornsby Park Drainage Upgrade Project
We prepared a Review of Environmental Factors (REF) to undertake drainage upgrade works around the north-eastern edge of the quarry void at Hornsby Park. A storm in 2020 caused significant scouring and erosion of the earth embankments and the collapse of a stormwater culvert (pipe) under the roadway. The drainage works are necessary to ensure that stormwater is safely conveyed through the site, safeguarding the site for future public use.
The drainage works have been designed for a 1 in 100 years rainfall event and include constructing culverts and open, rock lined channels. The drainage work will divert stormwater flow away from the quarry void, preventing future land slippage in large rainfall events and ensuring public safety is maintained. The area will be revegetated with local species.
The REF was exhibited between 27 October and 24 November, 2021 during which time four submissions were received.
September 2021
Council has appointed Ditchfield Contracting Pty Ltd to deliver bulk earthworks and stabilisation works for the Hornsby Park redevelopment. Works will commence on site this month.
These works will re-shape and stabilise the site and will deliver a safe landform that can be used for many different parkland activities.
Tasks include:
- Bulk earthworks and associated civil works including construction of access tracks, drainage and retaining walls;
- Quarry wall stabilisation works; and
- Revegetation work
This stage is expected to be completed in mid-2023 (subject to weather).
November 2020
The Hornsby Quarry Rehabilitation Works Development Application (DA/101/2019) was approved by the Sydney North Regional Planning panel on 4 November 2020.
November 2019
Hornsby Quarry Rehabilitation Works Development Application – Response to Submissions and Revised Project Scope (RTS) was open for public review and comment from Friday 22 November 2019 until 13 January 2020. The RTS and additional submissions were then assessed by an independent planner and reported to the Sydney North Regional Planning Panel.
What the revisions mean November
- Reduced extent of earthworks which preserves more trees across the site
- A lower solution for landform within the quarry, which preserves more of the dramatic cliff faces on all sides, including the eastern diatreme feature.
- A shorter construction timeframe, down from 24 months to 21 months, and reduced impacts associated with construction.
Importantly, we are still on track to deliver the first stage of the parkland creation in 2023, turning the local landmark into a spectacular new open space for the community to enjoy.
April 2019 – Hornsby Quarry Development Application and EIS
NorthConnex finished delivery of fill material to Hornsby Quarry in January 2019. Council with consultants prepared and lodged a Development Application (DA) with an Environmental Impact Statement (EIS) for the next stage of works, to re-shape and stabilise the site, with the aim to deliver a safe landform that can be used for many different parkland activities.
The Development Application and supporting Environmental Impact Statement for the transformation of Hornsby Quarry were on Public Exhibition until 17 May 2019.
The DA had to be determined by the Sydney North Regional Planning Panel before Council could begin the earthworks.
The EIS also included some important recommendations about how to best protect the natural environment of the site, including the Ecologically Endangered Communities, preserve Aboriginal and non-Aboriginal heritage and manage potential impacts on nearby residents, businesses and the community.