Gen Fyansford Quarry Transformation

Tonkin + Taylor played a key role in the transformation of the former Gen Fyansford basalt quarry into land ready for residential development – supporting one of the largest urban growth projects west of Geelong.

The site featured a steep-sided, water-filled quarry pit with unknown base conditions and variable fill. The challenge was to safely and sustainably prepare the site for future development, while maintaining cost-effectiveness and ensuring long-term ground performance.

We began with an unusual first step – of our geotechnical engineers took to the water, kayaking across the flooded pit to assess the depth and conditions of the quarry base. This enabled our team to map the site and begin planning with confidence.

As the water was drawn down, we progressively removed up to 3.5 metres of soft or unsuitable material from the quarry floor. We then developed and implemented an innovative infill strategy—placing 75,000 tonnes of engineered rock in multiple compacted layers, each proof-rolled to ensure stability.

At the heart of the solution was a bespoke filter layer, designed to allow the smooth transition from rock to clay. This critical interface was constructed under the supervision of Chadwick Geotechnics, ensuring quality and performance at every stage.

• 75,000 tonnes of engineered rock placed and compacted

• Innovative filter layer design enabling safe transition from rock to clay

• Real-time assessment via kayak-supported base inspection

• Full-time on-site supervision by Chadwick Geotechnics

• Strong collaboration with ICD Property, Sinclair Brook, and Winslow Constructors

The Fyansford Quarry project exemplifies how smart, collaborative engineering can unlock the potential of challenging land. Our solution was driven by sustainability and tailored design—creating a stable foundation for future housing that will support healthier living environments and a vibrant new community.