2024

Costco Chaska, MN 

This ground-up construction project, led by the Jones Covey Group for Costco in Chaska, MN, included the development of a high-capacity fueling station with 12 dispensers to support significant customer traffic. The station was equipped with three 30,000-gallon fuel tanks to ensure sufficient fuel storage and an additional 1,500-gallon additive tank to enhance fuel quality.

The build required precise planning and coordination to meet Costco’s specifications and timeline while maintaining the high standards of safety and structural integrity that such large-scale fueling facilities demand.

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The Challenge

FOUNDATION SETBACK

The primary challenge on the Costco Chaska project occurred during the installation of the canopy. Two of the canopy footings settled over 2 inches after the top steel and columns had already been installed. This unexpected issue created uncertainty about whether the footings would continue to settle further, which posed a potential risk to the overall structural integrity of the canopy. In response, Jones Covey Group worked closely with Costco’s consultants, GMA and Kleinfelder, to assess the situation and determine the best course of action. 

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The Solution

ENGINEERED STABILIZATION

To resolve the issue, GMA proposed two potential structural solutions. After thorough evaluation and continuous monitoring of the footings, including soil testing, the team decided to install shims atop the two canopy columns. This adjustment was made after confirming with Kleinfelder that further settling was unlikely. The shims successfully leveled the canopy’s top steel, ensuring that the structure remained stable and secure.

The Outcome

SHORT AND LONG-TERM BENEFITS

Through effective collaboration between Jones Covey Group, Costco, and consultants GMA and Kleinfelder, the project overcame significant structural challenges and was completed successfully. The unforeseen settling of canopy footings was resolved with engineered solutions that stabilized the foundation, ultimately ensuring the canopy's structural integrity. Continuous monitoring, testing, and precise adjustments helped maintain safety and quality standards throughout the build. As a result, the fueling station was completed on schedule, meeting Costco's opening timeline and positioning the station for long-term operational reliability.

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KEY COMPETENCIES

Collaborative Problem Solving

Close coordination with Costco and consultants GMA and Kleinfelder ensured quick adaptation to challenges.

Precision Monitoring

Continuous elevation monitoring and soil testing allowed for informed decision-making and reinforced structural stability.

Structural Expertise

Engineered solutions addressed unexpected settlement issues, preserving the integrity of the canopy.

Strong Partnerships

Long-standing relationships with key stakeholders helped drive the project to successful completion on schedule.

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