Kiwi Quarry
Management Plan
June 2015
CONTENTS
Summary ...................................................................................................................................................................3
Section 1: Introduction............................................................................................................................................4
Section 3: Financial ..................................................................................................................................................5
Section 4: Performance Measures .........................................................................................................................6
Section 5: Council and Contractor Responsibilities .............................................................................................6
Section 6: Site Specific Methodology ....................................................................................................................7
Section 8: Quarry Restoration, Rehabilitation and Expenditure Plan ...............................................................9
Section 9: Quarry Permits and Consents ........................................................................................................... 11
Kiwi Quarry Management Plan 2015
2
Summary
This plan sets out the history and future plans of Kiwi Quarry so there is a record of any major
decisions, expenditure, permits and consents.
It identifies the objective of the quarry as well as the methods of monitoring the condition of the
quarry and rock, and determines the annual funding and expenditure needed to retain the safest and
most cost effective plan possible.
Kiwi Quarry Management Plan 2015
3
Section 1: Introduction
1.1
Purpose of a Quarry Management Plan
This Quarry Management Plan defines the objective and performance standards of Kiwi Quarry
for which the West Coast Regional Council has the ultimate responsibility.
This Quarry Management Plan:
-
Identifies the service level for the quarry
Describes the background of the quarry
Describes the methods used to maintain the service level of the quarry
Complies with the regulatory requirements of the current Health and Safety in
Employment Act/s Regulations thereon and all relevant Permits/Consents.
Kiwi Quarry is a multi-bench side hill quarry located in Stillwater, West Coast, adjacent to State
Highway 7 and the Midland Railway.
Operated for the exclusive production of Armor Grade Protection Rock (AGPR) with a range of
.25 tonne through to rocks with an individual weight of 4.5 tonne plus.
The predominant rock type quarried at Kiwi Quarry is Kaiata Formation Carbonaceous Mudstone
with clearly visible bedding planes at a dip of approximately 10 degrees.
Kiwi Quarry Management Plan 2015
4
Section 3: Financial
3.1
Direct and Overhead Costs
The below costs do not include the “stock adjustment” which is applied when product is sold or quarried.
That adjustment reflects the “cost of rock sold” and is not a cost of operating the quarries.
The below costs include direct costs and allocated overhead costs.
Year To
Kiwi Quarry
Specific Cost
30/06/2006
30/06/2007
30/06/2008
30/06/2009
30/06/2010
30/06/2011
30/06/2012
30/06/2013
30/06/2014
Part Year
31/03/2015
$24,550
$34,664
$33,236
$29,058
$45,979
$97,313
$199,648
$141,154
$61,180
$87,327
Kiwi Quarry Management Plan 2015
5
Section 4: Performance Measures
The overall performance measure is to operate Kiwi Quarry in the safest and most cost
effective manner possible.
The following procedures will be adopted to ensure the adequacy of Safety and
Efficiency.
Annually
Rock production meets specific target(s)
Procedures meet Health and Safety requirements
Performance Measure
Waste to rock ratio – 20% waste 80% rock
Lost time due to injuries/incidents
Random Health and Safety Audits
Section 5: Council and Contractor Responsibilities
To achieve the primary aim of the Regional Council Kiwi Quarry it is essential that both
the Contractor and Council ensure that all responsibilities under existing Health and
Safety in Employment Law and relevant amended acts and regulations are recognized
and acted upon.
5.1
Contractor Responsibilities
It is expected that the goal of a ‘Zero Harm’ working quarry environment is seen as
achievable, operation expediency over safe work practices in WCRC quarries will not be
tolerated under any circumstances.
It is expected that all contractors operating in WCRC quarries will follow industry
accepted best quarry practices at all times.
Kiwi Quarry Management Plan 2015
6
Section 6: Site Specific Methodology
6.1
Drill and Blast Methodology
It is expected that the Contractors Blaster will develop a blast technique that uses a
minimum of explosive weight per tonne of rock produced to ensure that excessive
fragmentation does not occur.
Experience has shown that a combination of lightly loaded toe and down holes optimize
the production of AGPR with a minimum waste and in any case the proximity of road
and rain infrastructure rule out large production blasts at this quarry.
6.2
Faces and Benches
The current face retreat is to the west and it is intended that extraction be continued in
this direction. The aim is to fully expose the total available resource to the extent
possible in the upper levels within the current permit area.
On achievement, the lower level benches will also be progressively worked out in a
similar manner and direction.
6.3
Future Approximate Face Heights
Face heights at Kiwi Quarry will be limited to approximately 7-8m at all times.
6.4
Bunding
Recent changes to the Health and Safety in Employment Laws and all acts and
regulations there on have made bunding in quarries mandatory. This bunding
requirement includes all road edges, benches, faces, tip heads and associated terminal
drop-offs where there is a risk of vehicle roll over or falls.
6.5
Waste Dump Management
Space to dump large volumes of waste is very limited at Kiwi Quarry and it is important
to ensure that all waste handling is kept to a minimum and in particular that dumping on
or near potential resource is prohibited. All waste must be subject to some compaction
by way of track rolling and/or bucket tamping a minimum when being placed regardless
of whether it is to be used in access and bench bunding, easing of access road gradients
or at the tiphead.
Kiwi Quarry Management Plan 2015
7
Most of the waste generated at Kiwi Quarry will be utilized in haul road gradient
reconfiguration, extending the bunding along benches and roads and placing in
designated waste dumps.
6.6
Rock Stockpile Areas
At Kiwi Quarry AGPR will generally be stockpiled on the main bench in areas to be
marked out by the WCRC Quarry Manager prior to commencement of quarry
operatiions.
Although all quarry product ex the face shall be weighed as it is broken out prior to
loadout to stockpile the actual stockpiles shall also be constructed in such a manner that
facilitates physical measurement of rock volumes in the stockpile, (regular shape,
straight sides, consistent height etc.)
6.7
Hazards and Issues specific to Kiwi Quarry










6.8
Proximity to State Highway
Proximity to Midland Railway line
Risk of rock fall onto road/rail
Fly Rock incidents
Possible catastrophic destabilisation of outcrop
Geological considerations
Steep terrain
Limited visibility access crossing onto State Highway
Foggy conditions common in vicinity
Adverse weather conditions could lead to mud and debris tracking onto the State
Highway
Extraordinary Hazards
Fog is a regular weather phenomenon at Kiwi Quarry and when it is present or when
conditions increase the hazard at the crossing contractors are requested to take special
precautions when entering or leaving the quarry. These special precautions should
include but should not be limited to the following:



Approved Specific Warning signs (which may include roadside flashing beacons)
while rock cartage operations are underway
All trucks must have operational flashing beacons
A Transit NZ accepted Traffic Management Plan that deals with or minimizes the
inherent risks at the entrance crossing.
Kiwi Quarry Management Plan 2015
8
6.9
Access Road Regrading and Future Haul Road Maintenance
At Kiwi Quarry the main access road from the State Highway heads up to the main floor
firstly in an easterly direction before switching back to the west.
This overall steepness of grade as well as the abrupt change in direction can lead to
access difficulties for empty semitrailer rock trucks from time to time.
It is proposed to deal with this problem progressively in the next year or two using
waste generated in the blast/breakout/loadout phase to reconfigure the access road
trouble spots.
All access and main haul roads will be maintained in good order and tracking of mud
and other material beyond the quarry gate is to be avoided at all times.
Section 7: Primary Blasting Notification Requirements
Prior to any primary blasting taking place at Kiwi Quarry Train Control at Greymouth and
Transit NZ require notification and State Highway 7 needs to be closed in accordance
with the Traffic Management Plan.
-
Kiwi Rail Traffic Control, 0800 801 070
NZ Transport Agency , 0800 44 44 49 Greymouth, 03 769 9330
Contractors must pay strict attention to Kiwi Rail Time Tables particularly in regard to
the Alpine Express.
Finally, Council is committed to the concept and goal of a ‘’Zero Harm’’ Work
Environment in all WCRC Quarries and will work very hard with Contractors to achieve
this goal.
Section 8: Quarry Restoration, Rehabilitation and Expenditure Plan
The Restoration/Rehabilitation efforts of the last few years in the Council’s quarries
mean that overall the future requirements have been somewhat reduced at all sites but
in any case this Restore/Rehab expenditure must be viewed as a function of the ongoing
quarries operation. It is therefore important to ensure that each quarry has a dedicated
budget line to maintain a meaningful Restore/Rehab programme into the future.
The level of annual expenditure should remain reasonably constant being more or less in
lock step with annual production volumes unless a large flood event or similar occurs.
In this situation Restoration/Rehabilitation costs will increase in line with any production
surge but based on averages should equate to around $0.15 (15 cents) per tonne of
Kiwi Quarry Management Plan 2015
9
armour grade rock produced to also provide an additional lump sum at
closedown/decommissioning.
This lump sum will be required to deal with:








8.1
Roading issues
Public access
Long term safety issues
Pit slope and face stabilization
Drainage
Contouring
Landscaping
Land ownership/transfers etc.
Expenditure Requirements for Kiwi Quarry
As at 1/09/2014 year one restore/rehab programme and expenditure requirements for
Kiwi Quarry are as follows:
Seed collection/seedlings (endemic to location) Labour
and nursery costs
Planting including “clump” relocation within quarry,
landscaping etc.
Follow-up/release/replant as necessary
Total first year expenditure
$550
$1250
$300
$2100
Thereafter: Given the present annual production requirement at Kiwi of 4000 tonne
armour grade rock plus 25% to account for quarry generated waste (assume no
extraordinary flood events) an annual expenditure of $1050 (Inflation adjusted) should
be sufficient to meet the ongoing Restore/Rehab obligations during the production life of
this quarry.
There are sufficient reserves of rock at Kiwi to allow quarrying to continue for 20 years
at the current rate of extraction at which time additional decommissioning costs such as
roading, drainage, pit slope stabilization, contouring and landscaping will come to
charge.
Therefore assuming 20 years at 4000 tonne per annum = 8000t. + 25% waste =
100000 tonne all up.
Using and average of $0.15 per tonne the provisional sum required for decommissioning
at Kiwi Point Quarry totals: 100000t. X $0.15=$15000 LS required at closedown.
Kiwi Quarry Management Plan 2015
10
Section 9: Quarry Permits and Consents
9.1
Crown Minerals Permit 41295
Permit Number
Permit Term
Commencement Date
Expiry Date
Area
9.2
West Coast Regional Council Consents Held
Resource consent
Number
94/23
94/24
99257/1
99257/2
9.3
41295
40 years from Commencement Date
1991
2031
5,8240
Date
Granted
11.5.1998
3.5.1994
Oct 2001
Oct 2001
Term
20
35
35
35
Years
Years
Years
Years
Expiry
date
May 2018
2 May 2029
Oct 2036
Oct 2036
Purpose
Land use
Discharge to water
Discharge to air
Discharge to water
Grey District Council Consents Held
Consent
Number
Issuer
Date
Granted
Term
Expiry
date
Purpose
M94/4
LU N 869/02
GDC
GDC
3.11.1994
20 Years
3.11.2014
Land use
Kiwi Quarry Management Plan 2015
11
Kiwi Quarry Management Plan 2015
12