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HomeMy WebLinkAbout2014-01-27 PACKET 06.2.STAFF REPORT CASES: ICUP2014 -002 ITEM: 6.2 PUBLIC MEETING DATE: 1/27/14 TENTATIVE COUNCIL REVIEW DATE: 2/5/14 APPLICATION APPLICANT: Aggregate Industries — MWR, Inc. REQUEST: An interim conditional use permit for a temporary ready mix concrete plant and temporary concrete bridge casting production plant within the Nelson Mine SITE DATA LOCATION: ZONING: CONTIGUOUS LAND USE: SIZE: DENSITY: 11250 Grey Cloud Trail South 1 -4, Commercial Excavation District NORTH EAST SOUTH WEST 20 to 25 acres N/A Mooers Lake Rural Residential Mississippi River Mississippi River RECOMMENDATION Approval, subject to the conditions stipulated in this staff report. COTTAGE GROVE PLANNING DIVISION Planning Staff Contact: John McCool, Senior Planner, 651 - 458 -2874, 0 mccoo[Acottage- g rove. org GACITYFILES \14 CITYFILES\0021CUP Agg Ind Concrete Plant 2014 -01 -27 \Planning \ICUP14 -002 Agg Ind Concrete Plant SR cover 2014- 01- 27.docx Planning Staff Report Aggregate Industries — Interim Conditional Use Permit Planning Case No. MP2014 -002 January 27, 2014 Proposal Aggregate Industries - MWR, Inc. has submitted an interim conditional use permit application for a temporary ready mix concrete plant and temporary concrete bridge casting production plant within the Nelson Mine located at 11250 Grey Cloud Trail South. The proposed interim use in- cludes the construction of a 100 -foot wide by 600 -foot long metal building, a concrete casting storage yard occupying 20 to 25 acres of land, three cement silos, temporary ready mix plant, and one mobile trailer for office /product control lab. Site preparation within the Nelson Mine for this temporary use will begin with stripping the top- soil from the outdoor storage area. The topsoil will be stockpiled within the 20 to 25 acre site and reused for reclamation once the concrete bridge casting project is completed. During the site preparation phase (winter of 2014), trucks will transport limestone from the Larson Quarry in Grey Cloud Island Township. This material will be spread over the outdoor storage area, tempo- rary production building site, and internal access roads. A barge slip is proposed to be exca- vated northwest of the Nelson Mine sand and aggregate processing plant. This proposed slip will be approximately 60 feet by 220 feet long with nine feet of water depth. The purpose of this temporary concrete bridge casting production plant is to manufacture con- crete castings of bridge components that will be used in constructing the bridge across the St. Croix River near Stillwater, Minnesota. Once the bridge castings have cured, they will be loaded on barges and transported to the construction site downstream via the Mississippi River and up- stream on the St. Croix River. This bridge construction project is scheduled to be completed in 2016. If there are no delays in this project, the temporary ready mix plant and bridge casting facility will be removed before December 31, 2016. In ieuu 1 '11 i 0 � X1 I Ern1 . �r f 1�+7 DI . {Ql ��lir►t• rnrm � Jr, llf,L • I � � �AIIIV �. t Location Map Planning Staff Report — Planning Case No. ICUP2014 -002 Temporary Concrete Mixing and Concrete Casting Plant January 27, 2014 Page 2 of 13 A copy of Aggregate Industries interim conditional use permit dated January 2014 is attached. Ordinance Requirements The property is zoned 1 -4, Commercial Excavation. The Zoning Ordinance for the proposed temporary concrete ready mix and concrete bridge casting plant are not specifically identified as allowed uses within this zoning classification, but the interim conditional use section of the City Code does permit the City Council to consider interim uses if certain criteria are met. The interim conditional use permit section of the Zoning Ordinance does identify temporary structures, stockpiling of materials, and blacktop or crushing plants for roadway materials as potential inte- rim uses. Issuance of an interim conditional use permit is based on certain criteria listed in the conditional use (Title 11, Chapter 2, Section 9(F)) and interim conditional use permit (Title 11, Chapter 2, Section 10(B)) sections of the Zoning Ordinance. The City Council shall find that the applicant has addressed all the criteria in both sections of the Code. The criteria are as follows: Conditional Use Permit Criteria (11 -2 -9F) 1. The use will be in conformity with the City's Comprehensive Plan and with the purpose, intent and applicable standards of this Title. 2. The use shall be located, designed, maintained and operated to be compatible with the existing or intended character of that zoning district in which it is located. 3. The use shall not depreciate values of surrounding property. 4. The use shall not be hazardous, detrimental or disturbing to present and potential surround- ing land uses due to noises, glare, smoke, dust, odor, fumes, water pollution, vibration, general unsightliness or other nuisances. 5. The use shall generate only minimal vehicular traffic on local streets as defined by the transportation element of the Comprehensive Plan. The use shall not create traffic conges- tion, unsafe access or parking needs that will cause inconveniences to the adjoining properties. 6. The use shall be served adequately by essential public services, such as streets, police, fire protection and utilities. 7. The use shall not create excessive additional requirements at public cost for public facilities and services and shall not be detrimental to the economic welfare of the City. 8. The use shall preserve and incorporate the site's important natural and scenic features into the development design. 9. The use shall cause minimal adverse environmental effects. 10. The use shall not adversely affect the potential development of adjacent vacant land. Planning Staff Report — Planning Case No. ICUP2014 -002 Temporary Concrete Mixing and Concrete Casting Plant January 27, 2014 Page 3 of 13 11. In the case of flood plain applications, the following items shall be considered in addition to the aforementioned criteria: a. The danger to life and property due to increased flood heights or velocities caused by encroachments; b. The danger that materials may be swept onto other lands or downstream to the injury of others or that they may block bridges, culverts or other hydraulic structures; c. The proposed water supply and sanitation systems and the ability of these systems to prevent disease, contamination and unsanitary conditions; d. The susceptibility of the proposed facility and its contents to flood damage, and the effect of such damage on the individual owner; e. The requirements of the facility for a water front location; f. The availability of alternative locations not subject to flooding for the proposed use; g. The compatibility of the proposed use with existing flood plain development and flood plain development anticipated in the foreseeable future; h. The relationship of the proposed use to the Comprehensive Plan and flood plain management program for the area; The safety of access to the property in times of flood for ordinary and emergency vehicles; The expected heights, velocity, duration, rate of rise, and sediment transport of the flood waters expected at the site; and k. Such other factors which are relevant to the purposes of locating the proposed use in the flood plain. Interim Conditional Use Permit Criteria (11- 2 -108) 1. The period of time for which the interim conditional use permit is to be granted will termi- nate before any adverse effects are felt upon adjacent property. 2. There shall be adequate assurance that the property will be left in suitable condition after the use is terminated. 3. The use conforms to the zoning regulations. 4. The date or event that will terminate the use can be identified with certainty. Planning Staff Report— Planning Case No. ICUP2014 -002 Temporary Concrete Mixing and Concrete Casting Plant January 27, 2014 Page 4 of 13 5. Permission of the use will not impose additional costs on the public if it is necessary for the public to take the property in the future. 6. The user agrees to any conditions that the governing body deems appropriate for per- mission of the use. Background Sand and gravel have been mined from the Nelson Mine site since the early 1950's. Aggregate In- dustries has projected that sand and gravel resources could be mined for another 25 to 40 years based on market trends, geologic variations, and the future ability to mine in the Mississippi River backwaters. An aerial photo of the west half of Lower Grey Cloud Island shows the mining and ag- gregate processing activities in 1964, which is located in the same proximity of the proposed temporary concrete ready mix and concrete bridge casting site. r- Proposed Outdoor Storage Yard and Temporary Production Proposed Barge Slip Existing Aggregate Industries' Processing Plant 1964 di • q + �'•. - - .., - k h. j a 1964 Aerial Photo —West Half of Lower Lunda Construction Co. is the contractor constructing the new bridge across the St. Croix River, southeast of Stillwater. Lunda Construction is working with the landowner (PAS Associates, Ltd.) and Aggregate Industries — MWR, Inc. to develop a temporary construction site at the Nelson Mine on Lower Grey Cloud Island to manufacture concrete bridge components during the two years it will take to complete the bridge project. Sand and aggregate materials excavated from the Nelson Mine will be used in manufacturing the concrete bridge sections. Once the concrete bridge sec- tions have cured, the concrete components will be loaded onto barges at the Nelson Mine site and barged down the Mississippi River and up the St. Croix River to the construction site. Planning Staff Report— Planning Case No. ICUP2014 -002 Temporary Concrete Mixing and Concrete Casting Plant January 27, 2014 Page 5 of 13 Planning Considerations Site Preparation Site preparation will require the removal of trees and brush from a 20 to 25 acre area in the northwest corner of the Nelson Mine site. An inventory of the trees proposed to be removed was not submitted with the application. The applicant reported that most of the trees are Chinese elm and red cedar. The ground vegetation is predominately brome grasses. The vegetation and top- soil will be scrapped and stockpiled on the site for re- spreading over the disturbed area once the temporary use is no longer needed. The reclaimed grades will be similar to the original grades once the temporary uses cease operations. The site preparation and building construction is scheduled to begin in February-March 2014. During the site preparation phase, trucks will haul limestone from the Larson Quarry facility in Grey Cloud Island Township to the plant site. These trucks will travel north on County 75 to Grey Cloud Trail, then southerly to the Nelson Mine facility at 11250 Grey Cloud Trail South. Truck traffic will average approximately 80 to 100 trips per day during the approximate one month site preparation phase. The limestone from the Larson Quarry will be used for the tempo- rary production plant building's footprint and the access aisles for the various outdoor storage areas. This limestone material will be compacted to provide a stable surface for vehicles and heavy equipment. The storage area surface will be the existing sand sub -base. Approximately ten truck trips per day will deliver steel and cement to the production site once the site is graded and the building is erected. Site Plan The 20 to 25 acre site is located north of the Nelson Mine sand and aggregate processing plant, which is near the northwest corner of the Nelson Mine property. The proposed 60 -foot by 220 - foot barge slip will have a water depth of nine feet and is located in the southwest corner of the proposed outdoor storage area. Approximately 10,000 cubic yards of material must be exca- vated to create this proposed barge slip. The excavated material will be stockpiled on the out- door storage area and used in the restoration of the site once this facility is no longer needed. The proposed temporary 100 -foot by 600 -foot concrete casting building, aggregate feed system, central mixer, and three cement silos are located in the southeast corner of the 20 to 25 acre site. The highest point of the plant will be the bag -house at the top of the cement silos, which is approximately 65 feet. Sand and gravel to produce the cement mixes will be obtained from the Nelson Mine site. Vehicle access to the temporary concrete ready mix and concrete bridge casting production plant will be the existing private access road currently used for the Nelson Mine operations. The proposed barge slip will enable a tandem crane to extend over the barge for easy placement of concrete bridge sections on the barge. A copy of the site plan is shown below. Planning Staff Report — Planning Case No. ICU P2014-002 Temporary Concrete Mixing and Concrete Casting Plant January 27, 2014 Page 6 of 13 �y Temporary Concrete Production Facility Site Plan Temporary Concrete Casting Plant The temporary 100 -foot by 600 -foot metal building will be used for the production of concrete bridge components and maintaining the concrete castings in a batch control room until they have cured enough to be moved to the outdoor storage area. The building floor elevation will be at an elevation of approximately 704. This is above the 700 -foot flood elevation established in the City Code. The building height is 40 feet. All the steel work, form construction, and casting work will take place inside the building. The building's exterior walls and roof will be a galva- nized metal material. A 20 -ton bridge crane will be erected inside the building with the capability of being used anywhere within the 100 -foot by 600 -foot building. The project requires the production of approximately 650 concrete bridge sections. Casting of these concrete bridge sections will begin May 2014 and continue through the 2015 construction season. The casting work will be conducted during normal business hours. Approximately 65 -80 workers will be employed at this production facility. A diesel powered mobile crane will be used to move the concrete bridge sections. The cured sections will be transported via river barges to the bridge construction site beginning in August or September 2014. Three concrete pumps and the concrete ready mix plant will be on the south side of the con- crete production plant building. A mobile trailer will be placed near the ready mix concrete plant and used as a quality control lab. The building elevations are shown below Planning Staff Report— Planning Case No. ICUP2014 -002 Temporary Concrete Mixing and Concrete Casting Plant January 27, 2014 Page 7 of 13 �I I � " 4 — aw'u usrxi gY __ Building Elevations Surface Water Drainage The proposed outdoor storage area will be relatively flat. The majority of the site will be graded so that any excess water that does not infiltrate into the sandy ground will drain to the northeast cor- ner of the 20 to 25 acre outdoor storage area. The westerly 25 percent of the site will slope toward the proposed barge slip. Aggregate Industries will take appropriate measures to ensure there is no erosion from the topsoil berms along the north and east boundaries of the outdoor storage area. The ground elevation for the outdoor storage area will be above the 700 -foot flood elevation. There are no intermittent streams, swales, or wetlands within this proposed area. A copy of the grading plan showing the proposed grades on the 20 to 25 acre storage area is shown below. Planning Staff Report— Planning Case No. ICUP2014 -002 Temporary Concrete Mixing and Concrete Casting Plant January 27, 2014 Page 8 of 13 Proposed Site Grading /Site Plan Barge Slip and Dredge Spoils The barge slip will be approximately 60 feet wide by 220 feet long with nine feet of water depth. The total excavation will be approximately 10,000 cubic yards. This material along with the dredge material that will be removed as part of Aggregate Industries' Nelson Mine routine dock maintenance will be hauled to the interior of the mine site and used in upland reclamation. Dredging the proposed barge slip loading area to nine feet will be completed before the barge slip is constructed. The applicant has discussed the proposed barge slip with the Minnesota Department of Trans- portation, Minnesota Department of Natural Resources, Minnesota Pollution Control Agency, and the U.S. Army Corps of Engineers. These State and Federal agencies will continue to re- view and work with the applicant to insure all necessary permits for this project are issued before any work begins. The barge slip will remain once the temporary concrete ready mix and concrete bridge casting production plant vacate the site. The location of this barge slip is in close proximity to the future marina proposed on the Harbor Island concept plan for the future development on Lower Grey Cloud Island. This concept plan has not been approved by the City. Planning Staff Report— Planning Case No. ICUP2014 -002 Temporary Concrete Mixing and Concrete Casting Plant January 27, 2014 Page 9 of 13 Truck Traffic Site preparation will begin in February 2014, subject to City approval of the interim conditional use permit. Once the trees are cleared and topsoil stripped from the 20 to 25 acre production and sto- rage area, approximately 80 to 100 truck trips from the Larson Quarry facility in Grey Cloud Island Township to the Nelson Mine on Lower Grey Cloud Island will deliver limestone. Hauling the limestone will take approximately one month. The distance from the Larson Quarry entrance via Grey Cloud Island Drive (County Road 75) to Grey Cloud Trail to the Nelson Mine main entrance is approximately four miles. The distance from the Nelson Mine main entrance to the proposed tem- porary concrete production site is approximately one mile. The four -mile public road segment has a five -ton weight limit. On a daily basis during the casting of the bridge sections, approximately ten truck trips per day will deliver steel and cement to the production site. These vehicles will travel via U.S. Highway 61, Jamaica Avenue, 100th Street, Hadley Avenue, 103rd Street, and Grey Cloud Trail. Jamaica Ave- nue and 100th Street between Jamaica Avenue and Hemingway Avenue have a nine -ton weight restriction. The section of 100th Street between Hemingway Avenue and Hadley Avenue has a six - ton weight restriction. Hadley Avenue, 103rd Street, and Grey Cloud Trail have a five -ton weight limit. The illustration below shows the proposed truck routes and weight limitations on the public roadways. The City possesses certain regulatory authority over the site, including, but not limited to zoning authority. The proposed construction and use of temporary structures and operation of a temporary concrete ready mix and concrete bridge section production plant requires an interim conditional Planning Staff Report — Planning Case No. ICUP2014 -002 Temporary Concrete Mixing and Concrete Casting Plant January 27, 2014 Page 10 of 13 use permit. The interim conditional use permit contains conditions, one of which will be the pay- ment of a host community fee during the term of the interim conditional use permit, because the proposed interim use will cause direct and indirect impacts on the City's infrastructure in the vicinity of the site and ongoing direct and indirect costs associated with the presence and use of the inte- rim use and associated facilities that will not be compensated by property taxes. As a condition of approval of the applicant's interim conditional use permit, the applicant must enter into an agreement with the City of Cottage Grove that establishes an annual fee in lieu of taxes. Approval of the recommended agreement must be approved by both parties before any site prepa- ration work can commence. Aggregate Industry's Annual Mining Permit— Nelson Mine The proposed temporary concrete mixing and concrete casting plant is located within the Nelson Mine site. The proposed ready mix plant, temporary casting plant building, outdoor concrete sto- rage yard, and proposed barge slip will be located north of the existing Nelson Mine processing plant for sand and aggregate materials. Please refer to the planning staff report (Planning Case No. MP2014 -001) for more details about the Nelson Mine annual mining permit. Meeting Notices A public hearing notice was mailed to 23 property owners who are within a half -mile of the mine. These notices were mailed on January 16, 2014. The public hearing notice was also published in the January 16, 2014, edition of the South Washington County Bulletin. City Department Review The interim conditional use permit application filed by Aggregate Industries MWR, LLC for a temporary concrete ready mix and concrete casting production plant was distributed to other City departments. The Public Works Department expressed concerns for the proposed number of truckloads driving on Grey Cloud Trail, 100th Street, Hadley Avenue, and 103rd Street. These roadways are considered local streets and were not constructed to accommodate extensive volumes of heavy truck traffic. No comments or recommendations were received from other city departments or advisory commissions. Conditional Use and Interim Conditional Use Criteria The proposed interim use is considered to be consistent with the Nelson Mine operations, and the temporary use is located and designed to be compatible with the character of the surround- ing properties. Operations of the temporary concrete ready -mix and concrete bridge casting plant should not be detrimental or disturbing to present land uses due to noises, smoke, dust, vibration, general sightlessness, or other nuisances. The use should not cause any adverse en- vironmental effects and not adversely affect adjacent vacant land. The flood plain is not im- pacted and will not increase flood elevations or river flowage velocities. Appropriate water supply and sanitation systems will be provided onsite. The period of time for which the interim conditional use permit is proposed will terminate before any adverse impacts would occur to adjacent properties. As a condition of approval, adequate assurances that the property will be left in suitable condi- tions after the use is terminated is recommended. This assurance is recommended to be in the Planning Staff Report — Planning Case No. ICUP2014 -002 Temporary Concrete Mixing and Concrete Casting Plant January 27, 2014 Page 11 of 13 form of a letter of credit or cash escrow with the City. The amount of the financial guarantee must be enough to cover the removal of all structures constructed for the temporary concrete ready mix plant and all ancillary structures and equipment, except for the barge slip. The termi- nation date for this interim use is declared as December 31, 2016. Concern has been identified for the number of trucks driven on public local roads from the Larson Quarry and Highway 61. The proposed use will generate enough heavy truck loads on local streets that may adversely impact existing road surfaces. If the roads must be repaired, it should not be solely at the public's expense or detrimental to the economic welfare of the City. For this reason and as a condition of approval of the applicant's interim conditional use permit, the applicant must enter into an agreement with the City of Cottage Grove that establishes an annual fee in lieu of taxes. Recommendation That the Planning Commission recommend to the City Council approval of Aggregate Industry, MWR, LLC's interim conditional use permit for the temporary concrete ready mix and temporary concrete bridge casting production plant as described in their operation plan dated January 2014. This recommendation approving the interim conditional use permit is subject to the following conditions: 1. The interim conditional use permit as described in proposed operation plan date January 2014 shall terminate on December 31, 2016. Prior to December 31, 2016, all temporary structures, bulk storage facilities, mobile trailer, concrete ready mix plant, and concrete pumps used for the temporary concrete ready mix and concrete casting production plant shall be removed from the property. Site restoration for the 20 to 25 acre bridge section storage area used for the temporary concrete ready mix and concrete casting production plant shall be re- graded to its original grade elevations, the topsoil spread back over the area which was stripped, and the entire 20 to 25 acre site seeded with appropriate native seed mix. Site restoration must be completed before December 31, 2016. 2. The barge slip is allowed to remain, subject to the approvals by Mn /DOT, MPCA, Mn /DNR and the U.S. Army Corps of Engineers. 3. The applicant must enter into a Payment In Lieu of Taxes (PILOT) agreement with the City of Cottage Grove. Approval of this agreement must granted by the City Council before any site preparation work for this temporary concrete ready mix, concrete casting plant and all ancillary improvements for the temporary concrete plant begins on the Nelson Mine site. 4. The applicant is responsible for removing any materials that may have spilled onto any pub- lic roadway. This material shall be cleaned up immediately. 5. Bituminous /asphalt, concrete, and street sweeping materials are prohibited from being buried on the premises or delivered to and stockpiled on the temporary concrete ready mix plant site. Planning Staff Report — Planning Case No. ICUP2014 -002 Temporary Concrete Mixing and Concrete Casting Plant January 27, 2014 Page 12 of 13 6. All dust control and collection devices must be installed to control dust and cement emis- sions where cement is transferred to the silos and at the truck loading areas. The applica- tion of water and chloride to the internal access roads must be applied when necessary. 7. The applicant may operate the temporary concrete ready mix and concrete bridge casting production plant the same operation hours as approved for the Nelson Mine. Presently, City approval of the Nelson Mine permits operations 24 -hour a day and seven days a week. If any operation within the Nelson Mine causes noises that disturb any neighboring property owners, the applicant agrees to voluntarily cease operation during night -time hours until such time the noise source is identified and appropriate corrections are made. 8. Aggregate Industries must install erosion control devices at the base of any slope where erosion is evident. A drainage swale must be constructed at the base of any eroding slope to control run -off and divert it to a sedimentation basin before entering any natural drainage system. Erosion control measures must be implemented within a reasonable amount of time. 9. The applicant is responsible for obtaining all state and federal permits relating to the concrete ready mix, concrete bridge casting production plant, barge slip, and channel dredging /maintenance operations for the interim concrete ready mix and concrete bridge casting production plant on the Nelson Mine site. 10. A tree inventory for the 20 to 25 acre site must be completed and submitted to the City before tree removal begins. The applicant must comply with the City's tree preservation requirements. If tree mitigation is required, the applicant must submit a tree preservation plan and successfully plant the required number of trees before the October 15, 2016. A letter of credit that is 150 percent of the estimated cost for planting trees that complies with the City's tree preservation regulations must be submitted to the City before April 1, 2014. 11. All applicable permits (i.e.; building, electrical and mechanical) must be completed, submit- ted, and approved by the City prior to the commencement of any construction activities. Detailed construction plans for the proposed concrete bridge casting production plant and mobile trailer must be reviewed and approved by the Building Official and Fire Marshal. 12. A letter of credit in the minimum amount of $250,000 for the removal of the temporary metal building, site restoration (grading and seeding), ready mix plant, concrete pumps, cement silos, mobile trailer and all other ancillary structures and equipment associated with the temporary concrete ready mix and concrete bridge casting production plant must be sub- mitted to the City before any work begins or permits issued for the proposed interim use. 13. The applicant obtains the necessary permits from the Minnesota Department of Health Well Management Section Central Office and any other state agency that requires a permit for the installation of a new well for this temporary use. The well must be abandoned and sealed in accordance to the MDH's well management regulations before December 31, 2016. Sealing the well must be done by a licensed well contractor. A copy of the well sealing certification must be submitted to the City once the work is completed. Planning Staff Report — Planning Case No. ICUP2014 -002 Temporary Concrete Mixing and Concrete Casting Plant January 27, 2014 Page 13 of 13 14. The concrete ready mix plant must only be used for the mixing of cement for the tempo- rary concrete bridge casting production plant. Delivery of cement or sale of cement material for off -site use not associated with the temporary concrete bridge casting production plant is prohibited. 15. Appropriately designed and number of portable sanitary units must be provided on -site. 16. Truck deliveries of cement, steel, equipment, etc. must not exceed the weight restrictions designated for all public roads and streets. 17. Before the topsoil is spread over the storage area and production plant, the compacted limestone material must be removed prior to site restoration. 18. An erosion and sediment control plan must be submitted to the City before a building permit will be issued for the concrete production plant. 19. Pre - treatment of runoff (e.g. sediment basin or vegetative buffer) must be established prior to discharging into the proposed infiltration area in the northeast corner of the sto- rage area. The proposed infiltration area should be clearly marked to prevent the storage of materials in the basin and shall be sized to accommodate one -inch of runoff from the tributary area. 20. The City will monitor compliance of the NPDES permit for erosion control measures and the applicant is required to reimburse the City for inspection services. Prepared by: John McCool, AICP Senior Planner Attachments: Aggregate Industries Interim Conditional Use Application Supplement to the ICUP Application (Received dated January 21, 2014) AGGREGATE INDUSTRIES Aggregate Industries — Nelson Sand & Gravel Cottage Grove, Minnesota Interim Conditional Use Permit Application January, 2014 Aggregate Industries Nelson Sand & Gravel 11250 Grey Cloud Trail South Cottage Grove, Minnesota Property Legal Description The NE 1 /4, SE 1/4, Section 31, Township 27, Range 21, South along Grey Cloud Trail; W %2, SE 1 /4, Section 31, Township 27, Range 21; E' /2, NE' /a, NW' /4, Section 31, Township 27, Range 21, South along Grey Cloud Trail ;Wl /2, NE1/4, NW 'Y4, Section 31, Township 27, Range 21, South along Grey Cloud Trail; NW ' / 4, NW '/4, Section 31, Township 27, Range 21; S '/2, NW ' /4, Section 31, Township 27, Range 21; E Y2, SW ' / 4, Section 31, Township 27, Range 21; Lot 1, Section 31, Township 27, Range 21; N Y2, NE' /4, Section 36, Township 27, Range 22; S 1 /2, NE ' /4, Section 36, Township 27, Range 22; N' /2, SE Y4, Section 36, Township 27, Range 22; Lot 2, . Section 36, Township 27, Range 22; Lot 3, Section 36, Township 27, Range 22; SE Y4, SW 1 /4, Section 25, Township 27, Range 22; NE V4, NW ' / 4, Section 36, Township 27, Range 22; S Y2, NW 1 /4, Section 36, Township 27, Range 22; NW 1 /4, SW 1 /4, Section 36, Township 27, Range 22; N Y2, SW 1 /4, SW Y4, Section 25, Township 27, Range 22; S' /2, SW 1 /4, SW, 1 /4, Section 25, Township 27, Range 22; NW V4, NW' /4, Section 36, Township 27, Range 22; NW 1 /4, SW Y4, Section 36, Township 27, Range 22; N Y2, NE' /4, Section 35, Township 27, Range 22; S Y2, NE '/4, Section 35, Township 27, Range 22; SE 1 /4, SE 1 /4, Section 26, Township 27, Range 22; Lot 5, Section 35, Township 27, Range 22; Lot 3, Section 6, Township 26, Range 21; Lot 2, Section 6, Township 26, Range 21; Lot 1, Section 6, Township 26, Range 21; N Y2, NW 1 /4, Section 5, Township 26, Range 21; Lot 4, Section 5, Township 26, Range 21; Lot 3, Section 5, Township 26, Range 21; N Y2, NE 1 14, Section 5, Township 26, Range 21; Lot 2, Section 5, Township 26, Range 21; Lot 1, Section 5, Township 26, Range 21; Lot 1, Section 4, Township 26, Range 21; NE Y4 SW '/4 Sections 36, Township 27, Range 22; Lot 5 Section 35, Township 27, Range 22 Landowner: PAS Associates, Ltd. c/o Hugh Schilling 2565 Walnut Street Roseville, MN 55113 Operator: Aggregate Industries - MWR, Inc. 2915 Waters Road, Suite 105 Eagan, MN 55121 Page 12 Description of Proposed Operations Aggregate Industries seeks an Interim Conditional Use Permit to support the construction of the Stillwater Bridge. The term of the interim permit would be through December 31, 2016. The Company proposes to place a temporary ready mix concrete plant and a temporary concrete casting production plant at its existing Nelson Sand & Gravel Facility in the area depicted on the attached Figure 1 — Bridge Project Area The proposed Bridge Project Area comprises approximately 20 acres which was previously mined in the 1950's and 1960's and subsequently reclaimed. Refer to the attached historic air photo dated 1964. The vegetation in the proposed area is predominately brome grasses with some woody vegetation consisting of Chinese elms and red cedar. All of the woody vegetation is the result of natural seeding. No cultivars have been planted in the proposed project area. There are no intermittent streams, swales, rivers, water bodies or wetlands located in the proposed area, nor are there any existing buildings or features which are of historic significance. There are some product stockpiles on a portion of the westerly 10 acres of the proposed project area. The attached FEMA 2010 Floodway Map shows the 100 year and 500 year flood designations. The proposed ready mix plant will consist of an aggregate feed system, a central mixer and cement silos. The highest point of the plant will be the baghouse at the top of the cement silos, which would be approximately 65 feet. Aggregate material utilized to produce the various mixes of concrete would be obtained on -site. Cement will be delivered to the facility on a daily basis, with approximately 4 loads per day. The Plant will have a maximum output of approximately 100 cubic yards per hour. An estimated 30,000 cubic yards of material is expected to be produced on an annual basis. A temporary building and one mobile trailer would be located at the ready mix concrete plant. The temporary building would be utilized to maintain a batch control room and an employee area. The trailer would be utilized as a quality control lab (please refer to Figure 1 for the approximate location of structures). Equipment incidental to the ready mix operation would include the loader which is presently located at this site, as well as approximately 4 to 5 ready mix concrete trucks. The ready mix trucks will provide ready mix concrete to the concrete casting production plant. The ready mix plant would operate year -round with roughly 7 employees. The proposed temporary concrete casting production plant will consist of one building in which the bridge sections will be produced. Most of the site preparation and building construction will take place in the winter and early spring of 2014. Site preparation will include stripping of the topsoil and grading of the Bridge Project Area. The existing area is primarily level as depicted on Figure 2 — Current Topography & Conceptual Grading Plan There will be no loss of soil during the stripping process; the topsoil which is stripped will be used to construct perimeter berms as shown on the attached Figure 2 , and will later be used for reclamation of the area. Upon completion of the project, this topsoil will be spread back over the area which was stripped during the site preparation. The reclaimed grades will be similar to the construction grades, but will be slightly higher to include the depth of topsoil. The soils on this site consist of fill, mostly sand with minimal gravel (refer to the attached 1999 Soil Borings NL -99 -1, NL -99 -2 and NL -99- Page 13 4). The building footings will be designed for the required loads, employing compaction or spread footings, as may be necessary. The building footprint and portions of the exterior storage area will be covered with a crushed limestone base. The casting building will be approximately 600 feet by 100 feet by 40 feet high (details are shown on the attached Preliminary Building Drawings prepared by Keller Architects). The building will be located approximately as shown on the attached Figure 1 . After the site preparation takes place, the building floor will sit at an elevation of approximately 704, as depicted on Figure 2. All of the steel work, form construction and casting work, will take place inside the building. Each bridge section will be initially cured in the building then transported outside to finish curing. The job requires approximately 650 bridge sections. Casting of the bridge sections will begin in May of 2014 and will continue through the construction season of 2015. The cured sections will be transported via river barges to the bridge site commencing in August or September of 2014. The sections will be loaded onto barges at a barge slip which will be constructed approximately as shown on Figure 1 . The casting work will be conducted during normal business hours. Approximately 65 -80 workers will be employed at this production facility. All production in the building will be run off of line power. The traveling crane will be diesel powered. It will be fitted with a white noise backup alarm. The greatest amount of noise generated from this work will be from the concrete pumps which generate no more noise than that of a front end loader. Three concrete pumps will be located on the south side of the building. The bridge is scheduled to be completed in 2016. If there are no delays in the project, the ready mix plant and casting facility will be removed in 2016 and the site will be reclaimed. This temporary facility will be serviced by portable sanitary units. The Nelson facility currently operates 24 hours a day, seven days a week from April through mid- November. From mid - November through March, the facility is attended to a minim of five days a week during the hours of 6:00 a.m. to 6:00 p.m. These hours would remain unchanged with the addition of the proposed operations. Environmental Permits Aggregate Industries is committed to conducting its business in a way that is respectful of the environment. The Company maintains an internal Environmental Management System (EMS) which drives its day -to -day performance and ensures ongoing certification to the International Environmental Standard, ISO 14001. The EMS prescribes actions and responsibilities and tracks performance for every state, federal and local regulation. Each site maintains "operation" specific environmental site procedures which include environmental "conditions" inspections, during active operations to ensure that all environmental procedures are being followed. Page 14 Air Emissions The Nelson Sand & Gravel Facility currently operates within the limits of Air Emission Permit No. 03700352 -001 for non - metallic mining facilities. The addition of the ready mix concrete plant will require an aggregate heater. This heater will utilize propane or possibly liquefied natural gas. Dust: Dust emissions from the ready mix concrete plant will be controlled by a "baghouse" which will trap the particulate matter within the exhaust stream. In addition, "dust collectors" will be installed to control emissions at the points where cement is added to the silo and at the truck loading area. Additional control measures will include the application of water and chloride, as needed, to internal roads. Fuel Storage Tanks Presently there are 9 Storage Tanks located at the facility: a 10,000 gallon underground diesel fuel tank, along with the following aboveground storage tanks: two 6,000 gallon diesel fuel oil tanks, a 500 gallon gasoline tank, a 280 gallon hydraulic oil tank, a 280 gallon engine oil tank, a 50 gallon diesel fuel tank, a 525 gallon used oil tank and a 280 gallon used oil tank. All tanks are located within secondary containment. Diesel fuel, gasoline, motor oil and hydraulic oil are also present in the equipment and vehicles on -site. Site personnel are trained to respond accordingly should a spill occur. A designated employee conducts weekly tank and waste inspections. Aggregate Industries' Nelson Facility has an SPCC Plan in place for the storage tanks on -site. This plan will be modified, as necessary, to include any additional tanks which may be brought on -site. The additional fuel & additive tanks required for this interim operation will be properly registered with the State of Minnesota. Aggregate Industries provides secondary containment for tanks and drums as required under Minnesota Rules and/or Federal Law, as applicable. The Company's EMS, Spill Prevention, Control and Countermeasures Plan (SPCCP) and Storm Water Pollution Prevention (SWPP) Plan outline the measures used for the prevention and containment of spills. Groundwater Currently the Nelson Facility operates under Water Appropriation Permits No. 2000 -6135 and 1967 -0201 issued by the DNR. The addition of the ready mix concrete/ concrete casting plant will require that a well be drilled to supply water to the proposed operation. This will require that we apply for an additional Water Appropriation Permit. Lighting Exterior lighting will be located on the buildings to provide for safety measures. Noise: The mobile equipment associated with the proposed operation will be equipped with "white noise" alarms for backup safety. Truck Traffic During the site preparation phase (winter of 2014), haul trucks will transport aggregate material from the Company's Larson Quarry facility in Grey Cloud Island Township to the plant site.. These trucks will travel north on County 75 to Grey Cloud Trail, then southerly to the Nelson facility in Cottage Grove. Aggregate truck traffic will average approximately 80 to 100 trips per day during the site preparation stage. This base hauling activity will take approximately one month once work commences. This material will be utilized for the building Page 15 and the casting storage yard. Vehicles will also transport construction materials for the plant buildings onto the site during the site preparation stage. Once the site is prepared and the buildings are up, truck traffic will be reduced. On a daily basis, during the casting of the bridge sections, the job will require up to 10 truck trips per day, carrying steel and cement to the production site. These vehicles will travel via U.S. Highway 61, 100` Street, Hadley Avenue, 103 Street and Grey Cloud Trail South, to and from the site. Aggregate material utilized to produce the various mixes of concrete will be obtained on -site: Water Quality The Nelson Sand & Gravel facility is currently covered under a National Pollutant Discharge Elimination System (NPDES) and State Disposal System (SDS) Permit MN0001309. The majority of the storm water at the site drains back into the mining area and infiltrates through the sand/gravel surfaces. After grading takes place, any excess stormwater which does not infiltrate into the ground within the Bridge Project Area, will flow to the northeast into a "dry" stormwater infiltration area. There will be no stormwater discharged off -site in the proposed project area. Aggregate Industries maintains a Stormwater Pollution Prevention Plan (S WPPP) as required by our stormwater permit coverage. This S WPPP will be modified to incorporate the proposed project area and will delineate additional pollution prevention Best. Management Practices (BMPs) which will be put in place to control erosion and sedimentation in the proposed Bridge Project Area. Additional BMP's will include the installation of silt fencing and the construction of topsoil berms which will be seeded, on the northern and eastern perimeters of the proposed project area. Erosion and sedimentation control measures along the southern portion of the project area will continue to be controlled through the existing BMPs outlined in the Company's S WPPP, a copy of which has been provided to the Senior Planner at the City of Cottage Grove. The Company maintains stormwater coverage for their ready mix facilities under the MNG490073 Permit. The proposed ready mix plant will be added to the Company's existing permit. Every ready mix truck carries some "comeback" concrete when it returns to the plant after a delivery. This material is spread on the ground and once it has solidified, it is pushed into a pile by a loader. This comeback concrete, along with concrete from the building footings will be temporarily stockpiled on -site and will then be recycled into a Class 5 road base product. The Company holds a maintenance dredging permit with the Minnesota Department of Natural Resources for work in its' barge fleeting area. This permit is renewed annually, as needed. The DNR and the Army Corps of Engineers will review and issue any permits necessary for this project All Aggregate Industries' employees are required to undergo safety training as required by Aggregate Industries' Safety Policy and as governed by Minnesota and Federal OSHA, DOT, and the U.S. Department of Labor's Mine Safety and Health Administration. Employees attend regularly scheduled refresher training annually and site specific training, as needed. Specifically, Page 16 ready mix drivers and plant personnel attend annual AWAIR (Minnesota's "A Workplace Accident and Injury Reduction ") training. In addition, ready mix drivers attend defensive driving courses and ready mix plant personnel attend a four hour OSHA training class each year. Community Relations Aggregate Industries is committed to conducting its business in a way that is responsible and compatible with its neighbors and the City of Cottage Grove. Since communication is critical to said compatibility, the Company will: • Request that Neighbors contact Plant Manager, Bob Kurz, @ ( 651) 315 -3390 or the Company's Community Comment Line @ ( 651) 683 -8102, should they have any questions or concerns regarding operations at the facility. Callers should provide as much information as possible, including details such as: the date and time of day, description of concern(s), description of sounds and /or sights, frequency of activity, vehicle license plate number, color of vehicle, etc. • Respond in a timely manner to any concerns and /or issues which arise. • Record all Neighbor contacts and calls. Any mitigation efforts by the Company will also be recorded. • Establish and maintain a mailing list of property owners situated within one -half mile of the site. This list will include the City of Cottage Grove officials. Aggregate Industries maintains an "open door" policy and is pleased to conduct tours of the mine for neighbors, local officials, school groups and local scouting organizations at any time. 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O U A d 0 L O J fq a �a a O O LL . d L V O T O N a w LL John McCool RECEIVED JAN 2 1 2014 RE: Supplementto Interim Conditional Use Permit Application LRROF COTTAGE GROVE Dear Mr. McCool, Mr. Brad Schleeter of Stantec Engineering has asked for clarification as follows: The casting storage yard will include an internal road system for the crawler crane with a layer of class 5 limestone. The contractor is obliged to remove that material and pile it on site before the site is restored. The contract with Lunda requires them to save all the topsoil (which is a thin layer of black sand) and re- spread the topsoil over the disturbed area and seed it with a native grass seed mix. This is in keeping with our current oak savannah restoration plan. We will use Great River Greening to advise on the seed mix for optimum success. Erosion and sedimentation for this area will be managed by the created gradient, essentially the same as the current practices; we dig a hole and the water runs into it. The site preparation for this project will essentially create a depression which will be surrounded by a berm . At the northeast and the northwest corners of the casting yard there will be a hole for the water to run into. The berm will be constructed using the topsoil from the casting yard. Erosion from the berm will be captured by the silt fence which will be installed around the outside of the area. The floor of the casting yard will be the natural sand with internal roadways of compacted limestone. Except in frozen conditions, precipitation will infiltrate where it falls. Any erosion that does occur in the casting yard will move down gradient toward the stormwater basins or southerly across the existing stockpiling and processing area where it will be managed via the existing catch basin and sump pump system and according to the company's existing SWPPP. We propose no pretreatment of runoff. We propose to maintain the depth of the ponds by routine cleaning with a frontend loader over the life of the project. The bottom of the stormwater ponds will be sand. The stormwater basins will be approximately 43560 sq. ft. and will average 2.0 feet of depth. It will have a capacity of 700,000 gallons. A one inch rain event over the 27 acres that will drain toward the stormwater ponds will generate approximately 700,000 gallons of water. The exact sizing calculations will be worked out when the casting yard is developed. The contractor needs about 20 to 25 acres so we have plenty of room. The "come- back" concrete will be spread in an area just north of the temporary buildings inside the berm. The "comeback" rubble will be stored along with the concrete from the building in the area identified. The limestone base will also be stored approximately as identified. The barge slip will be approximately 60 feet wide by 220 feet long with 9 feet of water depth. The total excavation will be approximately 10,000 cu yards. This material along with the dredge material that will be removed as part of our routine dock maintenance (as permitted by the DNR) will be hauled to the interior of the mine and used in upland reclamation. We anticipate dredging the barge loading area to the necessary 9 foot depth before this slip will be constructed. The dredge spoils will be off loaded into the existing drying cell that is located where we will construct the barge slip. After the dredge spoils are hauled into the reclamation area, the slip will be constructed. RECEIVED JAN 2 12014 CITY OF COTTAGE GROVE