Construction on the approximately 2-mile water pipeline from Lake Superior to Lutsen Mountains began in fall 2013. After a few stops and starts, the project is back on track, according to Lutsen Mountains coowner Tom Rider. The pump house on the lakeshore has been all enclosed and interior work is now being done.
Although there have been obstacles in the Lake Superior-Poplar River Water District project, it is believed that the water line that will irrigate the greens at Superior National at Lutsen golf course and provide water for snowmaking at Lutsen Mountains ski area will be up and running in September 2016.
In an interview with the Cook County News-Herald this fall, Lutsen Mountains Co-owner Tom Rider said that it has been a very complicated project. “We’re two years behind schedule,” he said.
In November 2011, the Minnesota Department of Natural Resources (DNR) told Lutsen Mountains ski hill that it had to stop drawing water from the Poplar River for snowmaking by fall 2016. Rider said it was hoped that the pipeline would be operational this fall. He said the permit to draw water from Poplar River ends after the 2015- 2016 ski season.
One of the first obstacles was the completion of necessary environmental studies and Rider said he was pleased that the project received the support of Conservation Minnesota. In October 2012, the DNR determined that the proposed Lake Superior-Poplar River Water District pipeline would have no significant environmental effects.
The next step in constructing the pipeline was the engineering work and cost estimates. Lutsen Resort owner Scott Harrison, a member of the Cook County/Grand Marais Economic Development Authority (EDA), which oversees Superior National at Lutsen and is therefore a stakeholder in the water line project, explained that the engineers’ estimate for construction of the pipeline was $4.8 million. Harrison said the bids came back at $6.1 million. “That was a major, major surprise,” he said.
Rider said the Lake Superior-Poplar River Water District worked with contractors to do some “value engineering” and were able to reduce the project cost by $800,000.
Construction began in October/ November 2013 with $3.6 million secured in the 2012 state bonding bill. A local match was required so a number of project partners contributed such as the EDA and Superior National at Lutsen golf course; Caribou Highlands Lodge; Lutsen Resort on Lake Superior; Mountain Inn; Village at Lutsen Mountain Condominium Association; Eagle Ridge Resort; Papa Charlie’s Restaurant, and several other businesses, with Lutsen Mountains contributing the majority of the $1.3 million. The water district received an additional $1.1 million in state bonding in 2014. Construction delays and disasters
The actual trenching and installation of the 20-inch diameter pipeline has been complicated as well. Much of the approximately 2-mile line runs parallel to Poplar River, buried 8-10 feet deep. At one point where the pipeline crosses the Poplar River, trenching had to be completed during a period of low water flow. The river was diverted through a snowmaking pond while the pipeline was installed.
Compared to what contractors faced during the installation of the water pipe and construction of the pump house closer to the Lake Superior shoreline, that part of the project was relatively easy.
When the big pipeline was first set out into the lake by Marine Tech of Duluth in September 2014, it was not attached securely. As a major winter storm hit, waves broke the pipeline connection and a 200-foot-long, 3-foot diameter section washed away. “It was found in Two Harbors,” said Harrison.
The huge pipe was retrieved from Lake Superior and taken by barge to Taconite Harbor, where it is waiting to be re-installed. The water district has filed a claim against the builder’s risk insurance company.
Once work by RJS Construction Group, LLC of Superior, Wisconsin on the pump house is completed, the big pipe will be re-installed and be anchored more securely. Rider said the first 200 feet of pipe is buried at the beach. It enters a blasted lake trench and will be covered with boulders. The end of the pipe will have a 50,000- pound horseshoe-shaped structure holding it down.
The News-Herald asked if the second installation attempt will hold. Rider said RJS Construction is concerned that the setup is inadequate. However, he said the engineering firm, LHB, is certain it is. “Mother Nature will be the final arbitrator,” said Rider.
The pump house was erected on a strip of beach west of Lutsen Resort by RJS Construction Group. The structure will hold three pumps, 450 horsepower each and two small 50 horsepower pumps. To connect with the large pipe going out into Lake Superior and to house those pumps, it was necessary to dig 30 feet into the ground. Unfortunately, said Rider, the contractor didn’t properly compact the soil used for the building’s foundation. And, he said, some of the fill was frozen soil. “There was natural settling,” said Rider.
In June 2014, cracks were noticed in the foundation. “So they had to start all over again,” said Harrison. “They had to take out the concrete and begin again.”
Rider explained that after months of study it was determined that the best approach for the lakeshore pump house foundation was “injection grouting.” He said the contractor had to drill and pump grout into the soil. “It was decided that was the best approach,” said Rider at the September interview.
When the foundation problems were discovered, “Things went sideways,” said Harrison
Although the contractor is back at work, the question of the cause of the foundation collapse, who is responsible, and who will pay for the additional work is yet to be determined. “We’ve tried mediation. I think we’ll end up in arbitration or litigation,” said Rider.
“It is kind of messy,” said Rider, adding, “but a lot of big construction projects are messy.” Golf course concerns?
Superior National at Lutsen golf course, in the middle of its own construction project—the $5.8 million refurbishing of the River and Canyon holes of the golf course—was counting on the water pipeline for irrigation. The golf course contributed $250,000 in hopes that it would have the better water supply during the grow-in phase at the golf course.
Harrison said Mike Davies, the Superior National grounds supervisor, said the golf course struggled with the 200 gallons-per-minute they have been receiving. However, Harrison added, “That’s what we’ve had for years.” Added benefits of the pipeline
In addition to bringing water for snowmaking and golf course irrigation, Harrison said there is a water hydrant at Highway 61 to provide water in case of fires. “It is charged and ready 24/7 for firefighting, capable of pumping 7,500 gallons per minute.”
The pipeline will also eventually provide drinking water to the lodges at Lutsen Mountains, something that has been a perennial problem. Rider said using the Poplar River aquifer is not a sustainable solution. Harrison agreed, noting that there have been times when tanker trucks had to deliver water to establishments at the ski area.
The water treatment plant equipment is in a dedicated space (about 1,000 square feet) inside Caribou Highlands.
At press time on November 24, Rider said the pump house building was enclosed and contractors are working inside. After several stops and starts, Rider said, “We are making good progress.”
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