Highway & Facilities Committee Agenda Packet (PDF)

In compliance with the Americans with Disabilities Act, any person needing assistance to participate in this meeting, should contact the Office of the County Clerk at (920)746 2200. Notification 72 hours prior to a meeting will enable the County to make reasonable arrangements to ensure accessibility to that meeting. Notice of Public Meeting Monday, June 22, 2026 9:00 a .m. HIGHWAY & FACILITIES COMMITTEE Door County Government Center Chambers Room (C102), 1st Floor 421 Nebraska St, Sturgeon Bay, WI Oversight for: Door County Highway & Cherryland Airport, Facilities & Parks, Historical Museum A AGENDA  Call Meeting to Order  Establish a Quorum ~ Roll Call  Adopt Agenda / Properly Noticed  Correspondence  Public Comment  New Business (Review / Action) ▪ Highway & Solid Waste Division 1. Future Highway Operations a. Hot Mix Plant b. Crushing Operations  Closed Session ▪ Convene into Closed Session Pursuant to: § 19.85(1)(e), Wis. Stats., for the purpose of deliberating or negotiating the purchase of public properties, the investing of public funds, or conducting other specified public business, whenever competitive or bargaining reasons require a closed session. (Topic: Deliberating and negotiating the purchase of land for Door County Highway Department purposes.) Roll Call Vote Required  Reconvene into Open Session; Roll Call Vote Required  Discussion and Decision on Closed Session Matter (if any)  Next Meeting Date(s) ▪ July 8, 2026 – 9:00 a.m.  Adjourn Deviation from Order Shown May Occur This meeting will be conducted by teleconference or video conference. Members of the public may join the meeting remotely or in-person. To attend the meeting via computer: Please click the link below to join: https://us02web.zoom.us/j/865 40715314?pwd=NfypQOp1DF zd4SuLhpV0GntNMXzw4z.1 Webinar/Meeting: 865 4071 5314 Passcode: 319260 Or by Phone: Dial: 1-312-626-6799 HOT MIX PLANT Door County Highway Departments hot mix plant has been a main staple of the Highway Department for decades, on average producing 60,000 tons a year. Looking at the last 5- year average, 56.7% of that total has been used on County highway system, and the remaining 43.3% used on local roadway system and a small percentage on the State highway system. Over 2.3 million tons produced through this plant since 1988. Having this plant has saved the County and the local municipalities 100’s of thousands of dollars over time. The makeup of the plant is from several different vendors over time. This is because units have been replaced as needed and some systems are obsolete and after market units purchased. This has caused technical issues in the past and present. Who to call and where to call for repairs or parts. The controllers and computers that run the system have to accept the different units and make them all operate as one complete unit. Silo and some of the conveyors are from 1988. Liquid storage tanks and hoppers from 2002 and 2003. New drum and natural gas upgrades in 2011 and 2013. Computer upgrades in 2014 and 2020. Because of the different additions of units like rap, new burner, etc., there are situations where we presently light the burner with propane and then switch it over to natural gas. Upgrades needed in next couple years that we know about would be controllers, motors, and the electrical, with price tag of approx. $1.4 million. The hoppers are rotting and we have patched several times and should be replaced with roughly a $400,000 price tag. We are near the point of do we keep replacing or do we just decide to go new. A consultant did a study for us in 2024. There recommendation was to replace plant and move to near Duluth Highway Shop. Property, natural gas, close by,(at shop already), easy on and off highway to either direction at controlled intersection, close vicinity for mechanics for repairs, and other such things. In his report he states that on a 5 - year average of 66,000 tons, times two, because material still needs to be brought in, 10 minutes extra each trip. County truck carries approx. 20 ton per trip. A truck and driver cost approx. 148.14 per hour. 66,000 tons X 2/20 tons per trip = 6,600 trips. 6,600 trips x 10 minutes / 60 minutes per hour = 1,100 hours per year. 1,100 hours per year x 148.14 = $162,954 in just hauling costs. I think we are at the point of deciding one of the following: 1. Do we want to stay in the hot mix business? I think we do. It is a huge savings for not only the County, but the local municipalities also. 2. Do we keep piece mealing the operation as we are and hope for continued support and being able to acquire parts? 3. Do we decide to replace plant? Would be more efficient operating, smaller foot print and would not have the aging repair issues we are experiencing presently. 4. Do we replace plant and move to different location? Highway shop or some other location? Permits and zoning issues would need to be addressed depending on location. 5. Lastly, whatever we decide, how will it be funded? CRUSHING Recently, our crusher Foreman retired. Neither of the two people working the crusher are comfortable, or interested in becoming a crusher Foreman. The Crusher Foreman has huge responsibilities. They protect the County from liability issues in and around the quarries. Everything from emergency escape routes, signage, identifying hazards, electric grounding issues, safe equipment operations, heavy equipment repairs, and daily reports needed for MSHA regulations. Currently, MSHA has enacted and is enforcing strict silica sand testing. This requires an outside firm, we use Bay Environmental Services, to come in and do testing by having the crushing crew wear monitors for an 8- hour test. So far, we have been well under the exposure limits. This test needs to be done every time there are any repairs made to the crushing train while in a quarry, whenever screens are changed, meaning each time you change the material being produced, or a piece of equipment is moved or replaced. To meet standards, two tests need to be taken each time within a curtain time frame. Every six months from there it is up to operators if conditions warrant or not, for a test every six months. MSHA has tried, and is now on hold, but is threatening again and may change with administration changes in fall, that any person involved in crushing operations has a physical done, paid for by employer, along with lung screenings, to be done every three years. Hearing tests are also a requirement and the results of these tests are to be displayed at the mine site. We have been through the last few years, been replacing crushing equipment as needed. The major components of the crushing train are aging and will need to be replace in the near future. The breaker, and cone, are the biggest and running in the $1.5 – 2-million-dollar range to replace. Because of the reasons listed above, our management team is thinking it is time to explore using outside vendor for crushing. Our current crushing equipment has resale value, funds could go to the equipment replacement fund, we wouldn’t have the depreciation against the bottom line, and we would have two more people to handle the day- to day operations of the department. Attached are some numbers I got by calling a couple of crushing vendors on estimates for crushing. These could be lower yet if this process was bid out. CRUSHING COMPARISONS In 2025 we produced approx. 33,660 tons of hot mix aggregate. The cost was $5.55 per ton. Since 2020, the average amount of hot mix aggregates produced has been 37,898 tons and at average cost of $6.19 per ton. To produce 70,000 tons of hot mix asphalt we would need about 24,200 tons of stone. Blast in CY CY conversion to tons x 1.26 Tons of Stone 80% x 4.70 Waste 20% x 3.60 Blasting @ .86/ton Mob Cost to Produce w/blasting and Mob Cost per Ton Years of Materials Made 30,000 37,800 142,128 27,216 32,508 2,000 203,852 5.39 1.25 45,000 56,700 213,192 40,824 48,762 2,000 304,778 5.38 1.87 60,000 75,600 284,256 54,432 65,016 2,000 405,704 5.37 2.50 We are proposing parking our equipment for a period to see if this works out for us, or if someone steps up to foreman, or sell our existing equipment, or part of and continue to have outside vendor crush.