Willowbank Quarry

Update – February 2025:

The quarry is for Fulton Hogan’s commercial customers only and soon to open for account holders. Apply for an account here. (Note; we can deliver products to non-account holders, contact the quarry for all your delivery needs.)

The quarry management plan for the quarry, on the 650ha Willowbank Farm near the top of the Pauatahanui and Hutt River catchments, has been approved by local councils.

In February and March 2024, silt and sediment controls and drainage were a primary focus, and building the 395m visual bund that was formed with overburden material extracted from the quarry. The bund is covered in topsoil, hay mulched and hydro-seeded with grass.

In late February work also started on widening the farm road to the fill site on Willowbank Farm. Upgrading the intersection at the quarry’s entrance on to State Highway 58 has been approved by Waka Kotahi and Porirua City Council, and sales is due to begin in early March.

About Willowbank Quarry

Willowbank was first operated as a quarry by the previous owners of Willowbank Farm in 1993. After being closed for several years from 1999, consents were gained to reopen the quarry in 2018 by the CPB / HEB alliance to source aggregate for their nearby Transmission Gully project.

Following the completion of Transmission Gully, Willowbank Trustee Ltd partnered with Fulton Hogan to obtain a long-term (35 year) consent to operate the quarry, which was granted in January 2023. Willowbank Quarry will provide affordable and high-quality aggregate to a region with relatively limited quarry resources and strong demand.

The resource consent application included an ecology impact study (by Cardno NZ), erosion and sediment control plan (by Ridley Dunphy Environmental), a full traffic study including micro modelling of traffic on State Highway 58, a stormwater management plan, a comprehensive blasting report, a geotech report, and an air quality assessment (all by Beca), as well as a complete study on the effects of noise.

The independent reports showed that any adverse environmental effect would be minor and manageable, able to be appropriately managed through best practice quarry operations, management plans, monitoring and reporting, and standard conditions of consent. As the operator of numerous quarries around New Zealand, Fulton Hogan is bringing to Willowbank the benefits of extensive management planning, environmental monitoring and reporting experience.

Achievements Since 2022

Environmental initiatives

• Upgraded streams: we’ve created new stream channels and installed rock pools and plants to replace old disappearing streams.
• Upgraded silt retention pond (SRP): we’ve built a new pond that effectively holds water and controls silt sediment with rain monitoring and automated systems. The old pond leaked into the ground causing dirty water issues.
• Improved fish ladder: we’ve completed the fish ladder with baffles, resting pools, mussel ropes, and a bridge structure for better fish migration.
• Installed stilling basin: this helps manage water flow during high/storm events, reducing erosion into the environment.
• Water monitoring equipment: we’ve placed monitoring tools upstream and downstream to ensure quarry discharges stay within safe limits, checking turbidity, pH, and water temperature.
• Weather stations: we’ve set up stations to track wind speed, direction and dust emissions (PM10 and PM2.5).
• Solar farm and battery storage: our site offices and weighbridge kiosks now run completely off-grid, making them carbon zero.
• New heavy machinery: we’ve purchased machinery with AdBlue technology to cut nitrogen oxide emissions.
• Environmental award: Willowbank Quarry won the 2023 MIMICO Environmental Award.

In mid-2023, Willowbank Quarry won New Zealand’s quarrying sector’s premier environmental award, the 2023 MIMICO Environmental Award. The Willowbank Farm Trust holds the consent for the quarry, and Farm Manager Paul Nation calls the award “the icing on the cake” of a number of environmental initiatives in recent years, including planting 60ha in native trees.
“The quarry is an opportunity to diversify with the same environmental principles and attitude that drives the rest of our operation. It’s pretty exciting, and we’re delighted for everyone involved with this recognition.” The award was for a fish passage that allows native and introduced fish and invertebrates to reach the upper catchments of the hills behind Wellington. Quarry Manager Shane Hagai managed final construction of the fish ramps, addressing almost 300m of stream that had disappeared below ground through fractured rock. The fish ramps are designed for fish to pass under any conditions, from low water to storm-generated high-water flows, and have 17 fish resting pools and 54 baffles.

Biodiversity offset

• Planting native flora: we’re planting 42,000 native plants/trees and establishing a covenant with predator fencing and monitoring.
• Lizard relocation: we’re creating a habitat for lizards onsite, complete with monitoring and a release programme.

Traffic management

• Traffic monitoring cameras: we’ve installed cameras at the intersection of SH58 and Willowbank entrance to improve public safety and comply with heavy vehicle limits.
• Paperless weighbridge kiosks: we have automated kiosks for customer needs, with numberplate recognition and automated communication with loaders.
• Quarry driveway upgrade: we’ve improved the 3km driveway with cement stabilisation and chip seal for better access.

Community Engagement

As part of the consent relating to the operation of the Willowbank Quarry, a Community Liaison Group (CLG) was required to be set up. The CLG was to consist of local residents, local associations, local regulatory bodies (PCC and GWRC), and Iwi representatives.

The CLG meets regularly when required under the chairmanship of John Spence. The CLG is a mechanism for local people and residents etc. to meet with FH staff on a regular basis to discuss ongoing operations at the quarry and address any issues raised.

Ongoing and future works

Our commitment to continuous improvement remains strong as we advance our ongoing projects with the same dedication and care.

Thank you for taking the time to learn about our ongoing efforts and achievements since taking over Willowbank.