Project Overview
Our team was contracted by the City of St. Michael, MN, to complete large-scale grading and material processing at the future Naber Business Park.
The 30-acre industrial site required:
- Full topsoil stripping and precise grading for future street and building pad elevations
- Processing of more than 500,000 tons of excess soils
- Export of all excess materials off-site within an 18-month deadline, avoiding $1,500/day in potential liquidated damages
During the process, we converted the excavated material into high-quality aggregate products:
- 360,000 tons of screened sand
- 90,000 tons of Class 5 gravel
- 50,000 tons of screened 1 ½” rock, hauled to Fehn Aggregates for future washing and distribution
Challenges & Solutions
1. Large-Scale Material Processing
Challenge: Processing a half-million tons of variable native material, including silty soils that periodically impacted production quality.
Solution: Plant operators actively monitored consistency and adjusted crushing/screening operations in real time to ensure all products met MnDOT specifications.
2. Logistics & Haul-Off Efficiency
Challenge: Meeting the aggressive haul-off schedule required continuous trucking operations.
Solution: At peak performance, up to 50 trucks per day were dispatched. Our dispatch and trucking teams coordinated closely to reduce wait times and maintain a continuous outbound flow.
3. Sales & Market Demand
Challenge: Identifying buyers for large volumes of processed materials was essential to avoid costly stockpiling delays.
Solution: We expanded sales and marketing outreach, securing regional buyers and construction projects to absorb the sand, gravel, and rock.
Project Impact
Through proactive planning, adaptive processing techniques, and strong coordination between our processing, logistics, and sales teams, we:
- Completed the project within the 18-month timeframe
- Avoided costly penalties
- Delivered high-quality aggregate products into the local market, reinforcing our reputation for reliability and precision
At Fehn Companies, we don’t just move dirt — we transform challenges into opportunities, turning large-scale earthwork into lasting value for our clients and communities.
