Gateway BP(1.1)-CS 931021 CITY OF COPPELL
PLANNING DEPARTMENT
STAFF REPORT
CASE #: S-1071 (LI to HI with S.U.P. fQr a tile manufacturer)
P & Z HEARING DATE: October 21, 1993
C. C. HEARING DATE: November 9, 1993
LOCATION: Along Gateway Blvd., just north of its intersection with Cotton Road
SIZE OF AREA: 20.55 acres, with initial development on 14.93 acres
CURRENT
ZONING: LI, Light Industrial
REQUEST: Change of zoning to HI, Heavy Industrial with a Special Use Permit for a
ceramic tile manufacturing facility
APPLICANT: Catellus Development Corp. Intercemmic, USA
(Owner) (Tenant)
5429 LBJ Freeway, Suite 600 1624 W. Crosby Rd., Suite 120
Dallas, Tx. 75240 Carrollton, Tx. 75006
(214) 770-3200 (214) 446-0703
HISTORY: There has been no recent zoning history on this tract, although a subdivision plat
for a 16 acre parking lot west of this property was denied by Planning
Commission earlier this year because of non-compliance with the provisions of
city codes.
Item 10
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TRANSPORTATION:
Gateway Blvd. is a four-lane improved street contained within a 70 foot r.o.w.
SURROUNDING LAND USE & ZONING:
North -Regional postal facility; LI
South - vacant; LI
East - vacant; LI
West - vacant;LI
COMPREHENSIVE PLAN: The Comprehensive Plan shows highway oriented commercial as
appropriate for this parcel
ANALYSIS: There are several issues which need to be addressed before recommending either
for or against this request. In summary, use of land, environmental impact, philosophy behind
SUP's, ramifications of the base zoning, image of Coppell, the project itself, impact upon the
community all need elaboration, followed by the staff recommendation.
Use of Land
Although the Comprehensive Plan called for highway oriented uses as most appropriate
here, it must be recogniz~ that the Plan was completed in 1987 at a time when development
philosophies and possibilities were much different than they are today. It is doubtful that the
city will ever absorb the amount of land now zoned for highway commercial uses, and certainly
interior parcels such as this one will be among the last to develop. Because the land is currently
zoned for LI uses, there are any number of uses-not highway commercial in nature- which could
be developed on the property today without any public input. It is actually advantageous that
a change of zoning for manufacturing use has been requested in that a much more
comprehensive review of the development proposal will occur, thus establishing a comfort level
to the community that would not otherwise result. Also, the fact that the proposal is located on
an improved four lane street, has excellent access to the freeway system, and is surrounded by
LI zoning, suggests that such use could be appropriate here.
Environmental Impact
One of the more critical issues facing the approval of this manufacturing facility is the
assurance that the use will not negatively affect our pattern of living or quality of life in the
community. It should be noted that the owner of the parcel upon which this use is contemplated
owns an additional 200 acres adjacent to this parcel, and it would be imprudent--probably
economically disastrous--were this first use to create an environmental problem. It just does not
make economic sense for the developer/owner of this tract to establish a business here that
would raise concern regarding environmental issues. Perhaps more importantly for the citizens
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of Coppell, however, is the assurance that if the facility is built, there will be no danger to life.
In addition to our regular development review process, staff has solicited a review by the city's
Environmental Health officer, D/FW airport staff, FAA, the State of Texas with regard to air
and water concerns, to raise any other issues that might not be readily apparent in a typical
zoning case. We have received no input from any of these agencies that the proposed use would
be environmentally sensitive or dangerous to our residents. In addition, our Public Works
Department (through the environmental health officer) keeps in regular contact with the Texas
Natural Resources Conservation Commission, the agency charged with air and water quality in
the state, and the agency mandated by law to review all new facilities that may emit air
contaminants.
S.U.P. Philosophy
A provision of the zoning ordinance which may assist in establishing a comfort level with
this request which is not always present in zoning eases, is the fact that a Special Use Permit
must be obtained before the manufacturing operation can proceed with development. What this
assures is detailed plan submission prior to any zoning change being granted. This developer
has provided staff with a variety of exhibits which explain in graphic form exactly what is
contemplated to be constructed here. Thus, details such as landscaping proposed, design of
signage, screening, site plan submittal, height of buildings, elevations of the finished product,
staging of development, circulation patterns, square footage of building, use of property,
architectural details, are all submitted for review, possible alteration, and approval prior to any
work commencing. In the long run, what this does is provide the Commission and Council a
vehicle to address any question or issue dealing with the manufacturing facility in a manner
which results in knowing exactly what the final product will be.
Ramifications of Base Zoning Chan~,e
One concern that has been expressed by the community relates to the change of zoning
from LI to HI. Although the philosophy of the additional S.U.P. provision protection has been
outlined above, there has been some reluctance to accept HI with the S.U.P. Part of that
reluctance relates to the fact that if, for some reason, the tile tenant vacates the property, the
base HI zoning remains, and this would be the only HI zoning in the city. Staff responds with
two comments. One, prior to 1984, the entire western section of Coppell, including this parcel
was zoned HI so this zoning classification has existed on large portions of the city in the past.
Second, if this user vacates the premises, the Commission is well within its authority to call a
public hearing to determine proper zoning for the site.
Image of Coppell
Perhaps one of the major obstructions facing this application is the concern of some
citizens that if approved, Coppell will lose its reputation for being a well-planned, dean,
somewhat up-scale bedroom community to the larger region. Basically, we have never had a
manufacturing plant in the city, and the general feeling of manufacturing plants being unsafe,
generators of poisonous air and water, of overloading our infrastructure, creating gigantic masses
of stockpiled raw materials, and spewing vast amounts of pollutants from tall smoke stacks (as
depict in an anonymous letter addressed to Commission and Council, for example), can not be
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ignored. However, it is unfair to judge this proposal based on misconceived and erroneous
concepts of what this facility will be. One of the functions of the public hearing is to gain the
kinds of information, and ask the questions which will assure no detrimental long term effects
on the city. This proposal includes extensive landscaping, was architecturally designed, is a
state-of-the-art tile manufacturer, provides information showing ultimate development of the
site,complements the application with additional data regarding signage, aesthetic considerations,
etc. In addition, it must abide by the most stringent development standards of any business in
Coppell--maybe the region.
The Project Itself
As submitted, this project will initially be built on a 14.9 acre parcel containing almost
262,000 square feet of office and ceramic file manufacturing activities. The office makes up
roughly 28,000 square feet, the plant 233,000 feet. The plan also shows possible expansion on
an additional 5.6 acres and additional building area of 179,000 feet, which would eventually total
a 20.5 acre site with 442,000 square feet of office and plant. The case before you today details
the phase one development, but zoning is being requested to eventually expand to the 442,000
foot facility.
Landscaping proposed far exceeds our streetscape guidelines, and staff commends the
applicant for recognizing that this location has tremendous visibility from LBJ Freeway, hence
the extensive plant material proposal. In addition, the applicant has considered the most
appropriate place to store the clays which are used in the manufacturing process and has shown
them screened by the building's north wall and has also added bin dividers as well. In addition,
the highest portion of the building (65 feet of clear height) will assist in further screening the
stockpiled raw materials.
There has been tremendous publicity regarding this zoning application, and allegations
have been made by detractors regarding air/water pollution and lead danger. The manufacturing
process proposed here contains no leads in the clays, the tile glazes, or in any of the
manufacturing materials. Following up on concerns regarding air and/or water pollution issues,
the applicant will utilize sewer and water connections as any developer has such opportunity.
In this case, however, this plant has a self-contained recyclable internal water system, and the
vast amount of water used in the manufacturing process will not enter the city system. Indeed,
the applicant has stated that only typical sewer connections such as bathrooms, kitchens, water
fountains--the typical connections of any business--will be utilized here. Staff does not foresee
problems with connecting to our water and sanitary system.
In the area of air pollution (and also water quality), the Texas Natural Resource
Conservation Commission mandates review of any manufacturing facility proposed in the state,
and it is staff's understanding that water and air quality standards are vigorous and actively
enforced. If violations occur, fines in the thousands of dollars are not uncommon. It is staff's
further understanding that EPA guidelines, OSHA requirements, state standards all have to be
addressed before a permit to build a manufacturing facility can be released. Thus, the
Commission and Council could approve a plant, but no building construction could actually
occur until all environmental requirements were met--a process that can take as long as six
months or longer. The only exception to the permitting process is if the proposed facility
obtains a permit exception from the state. It is our further understanding that the only time
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exceptions are granted is if the proposed facility can document that because of the state-of-the-art
equipment proposed, the types of materials used in manufacture, or other compelling reasons,
that air quality standards are not compromised. We have been advised that Interceramics is
applying for an exception because of the reasons just stated, and the applicant hopes to have
resolution of this issue by the first week of November.
Staff has been in communication with Washington, Austin, and Ft. Worth to garner an
understanding and comfort level with the process which would reflect positively upon the review
procedure and monitoring policy. We have gained that confidence and hope to have a
representative of the State Natural Resource Commission present to further elaborate on the
entire procedure. We have also asked D/FW Airport to review the proposal--they had no
objection, and a representative of the FAA who attended the same meeting concurred.
The elevations presented with this application speak well of the developer's intentions
and the perspective drawing of the front of the building is to be commended--this does not look
like a typical manufacturing plant. We would point out here that there are two elements of the
plan which do not meet the requirements of the zoning ordinance, parking and sign size.
Regarding parking, as required by ordinance, a building containing 262,000 square feet of office
and manufacturing plant must provide 326 parking spaces (1/300 feet of office, 1/1000 feet of
plant). The proposal before you suggests providing 273 spaces initially, to add parking at Phase
II construction complying with the total required by ordinance, 509 spaces. It is anticipated that
at initial start-up 125 employees will be employed here, and staff has no objection with the
parking plan as submitted. The variance from required parking would, however, have to be
addressed by the Board of Adjustment; the Commission or Council can not grant a parking
variance. There are also parking lot landscaping modifications which must be made to conform
to our landscaping guidelines, but these alterations are minor and will not adversely affect the
parking shown.
Concerning signage, the monument sign meets code, but our sign ordinance specifies a
maximum logo sign to be no larger than 5 feet square. The proposed logo is approximately 12
feet wide by 13.5 feet high. The *Interceramic~ wall sign is allowed to be 4 feet high, the
elevation shows it to be 5 feet in height, 36 feet long. At first blush one might conclude that
these sign size variations are excessive. However, including the monument sign (48 square
feet), the logo (162 feet), and the wall sign (180 feet), the applicant is within the 400 foot
maximum allowed by ordinance--totalling 390 square feet of signage.
One final minor comment. The plan shows two guard houses. It might be prudent to
see what these buildings look like as they have exposure to LBJ and consistency with the overall
plant design would seem desirable.
Impact Upon the Community
We have attempted to outline the major concerns with this proposed development
expressed by staff, the applicant, and citizens of the community as we reviewed this application.
There is no doubt that if this request is granted, it will have profound impact upon the
community. Although there is a faction within Coppell contending that this proposal will be
detrimental to the city, the issues discussed above do not seem to bear that out. Granted, HI
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zoning does open a different type of development door that Coppell has not been challenged with
in the past. It is also recogniz~ that a manufacturing facility can give a community a different
image, and in some circles that image is interpreted as being bad for the community. But to
equate this application to belching smoke stacks, lead-poisoned soils, pungent smelling water,
and various other negative descriptions, is unfair to the proposal.
This facility will provide jobs, increase the tax base, create a positive exposure to this
community from LRI Freeway, not overburden the infrastructure system, create and hopefully
promote additional economic development--all with a state-of-the-art manufacturing facility that
many communities would jump at. Taken in toto, it is staff's opinion that this facility will have
a tremendous impact upon the community, and from our perspective it will be positive.
Staff Recommendation
At the outset of this analysis, it was pointed out that there were a variety of issues
warranting discussion prior to formulating the staff recommendation. We have covered in some
detail those issues above. It goes without saying that regardless of staff position, there will be
disagreements with our conclusion. However, having analyzed this request as comprehensively
as any zoning application in recent history, addressing the issues that have been raised regarding
this proposal, being objective as we have reviewed the issues, and soliciting the opinions of
others who may have more expertise in various elements of the review--particularly air/water
concerns--we come to the conclusion that this proposal will work toward the benefit of the
overall community and its location is appropriate for this type of use. Although we had initial
concerns with this application--primarily in the areas of noise and dust generation--those
concerns have been addressed. Regarding noise, it has been observed that highway noise from
LRI Freeway is greater than that which will be generated on this site. With regard to dust, we
are confident that air quality control measures will be taken to minimize any annoyance from
that source.
In short, the plan is attractive, we have confidence that it will not despoil the countryside,
there are adequate enforcement tools to insure its proper operation, it is located in an area of the
city that we are encouraging economic development activity, it is physically as far away from
our existing and planned residential communities as any property in Coppell, and a variety of
agencies were given an opportunity to review the application for specific compliance. Staff
would recommend approval of HI zoning with an S.U.P. for a tile manufacturing plant subject
to the attached site plan and appropriate conditions.
As a final comment, staff recognizes that a variance in the initial parking requirement
must be considered by the Board of Adjustment, and would remind that in the unlikely event the
tile manufacturer vacates the property, the Commission and Council have the authority to call
a public hearing to determine proper zoning on the property.
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ALTERNATIVES: 1) Approve the zoning
2) Deny the zoning
3) Modify zoning
ATrACHMENTS: 1) site plan/elevation
2) landscape plan
3) tile production outline
4) perspective drawing
.stf
The Production of Glazed Coramio Tllo
The ceramic lite produclion procesa has r~veral stages which are flluelrated on [he
last pa~e of this secgon. It be§ir~ wl~h mw materials conststin§ of olay, wldch is
trarmpo~d by truck from the min~a ~o tim manufacmrm~ foc/Idties in ~he city of
Chihuahua, about 20 miles distance, where ~h~ clay is kept in opcn morag¢ bins
while awaiting proc~s/n~. Clay and water am then mixe~i and pumped lnm largo,
cylindrical mtn~, where the 8rindin~ action of v~tous sized alumina balls
puivorlz~ granules and clumps of clay into a uniform substrato catlod slip. Thc
~tp is then pumped into
~ubjec~ed to blown hot air to evaporate ~ubstimtially MI of the water ~ Thc
result is a very ~ powdar-like suba~ne~ called spray-dry powder.
Th~ powder is Ihen rod into a hydraul~ press, on~ pr~a for o~h produoflon llno,
whor~ tl~ powder i~ moldad into th~ sele~ed 8eomc~io ~lmpo m~d siz~ for h'm t/lc
bo/ng produc~.d. It is subjo~texi to cxtrcrao ps~asuer~ of alJProximatcly 4,000
pounds p0r ~lu~r~ inch, producing a mold~ c6rs,nl~ tile. Ti~ Complmy's p~..~
pmdu~ approx~m~_~-~y 100000 square feel ol ~ p=r pmdu~gon lin= per eight-hour
per/mi during an ordinary production shift.
At this point tl~ t/lo, wh/ch Is lmrd b-t brYll¢,
f~d &utomat/0nlly along a oonvcyor bolt whom glazes al~d d~sig~ am admlni~lo~d
lhrough ~utommxi washin~ brushing, ~i sllk-sc~g (or olher w~ or dry-
pro.ss) equtpm~m, glazed m~ oven, or ~ Th~
sin~lo-flfin~ c~lo lns~ from 45 to 50 minutos. ~ wlfld~ Ihue fl~ Ltlc cmcr~a,
flrod, at tl~ oPlx)sito cnd.
Pahmnl~L The vltrlllexi
c~norL~s
proccss
~mtlly. ~ fired tile
control inspectton points whom thc ti/o is mavmi~diy scanncct for dc/cas ami
visually e~ _n,~ined for sonln~ acconii~ tu vuriatinm In thc color of Ihe glaze,
chipping or other surface cte. f~-ts, ~ which it is boxed for dlstrtbutlm~-
invontorlee
month-and-a-half of sales. Thc ~ ~oods inventories mc currcmly bdd in
lea~d wamhotmo spa~ Chihuahua; however, a ~oods warehouse
in
· dJaceat to thc Company's plant Is expected to bc cumplctcd in thc first quarter of
SITE DATA
...... -- - '~l~cm~- ---~37m~'?~ .... _--___=-~ ~ f INTIALBUILDING
.............. .,.~ ....... ___._______~____:__: .... .... ~. -----~
~ I~ ' '!
k ................................ ~
179.600sf DE
-- DE DE
........................................................................ ~' ~ ~ ~D ~: ~3S ACR~
-- DE DE ~ ,, ~ .,~,0 s,
PLAN
9.22.93
CATELLUS DEVELOPMENT CORPORATION
GATEWAY BUSINESS PARK Coppell, Texas
10/07/g3
Mark Equipment Phase I Final
# Description Quantity Quantity
A Spray Drier {Gas-Fired) I 2
A1 Combustion Air Flue
A2 Gas Vent
A3 Hot Air Stack
B Roller Drier (Gas-Fired) 2 8
B1 Combustion Air Flue
B2 Gas Vent
C One-Layer Drier (Gas-Fired) 2 6
C1 Combustion Air Flue
C2 Gas Vent
O Single-Layer Kiln (Gas-Fired) 2 B
D1 Combustion Air Intake
D2 Combustion Air Flue
D3 Gas Vent
E Emergency Generator {Diesel) 2 8
E1 Exhaust
F Dust Collection System (Electric) 5 5
F1 Exhaust
.... 222. ....... _--~-__ ~ .... - ..... -.-' ........ --'-"_.~ , ..................... ~z-.___.~ ~. ........ ~ ~
-~ ' MANUFACTURING ~AREHQUSE - ~ . '~ ,
_. ~-~.,,~ ,__~, . - .
= ~ .................... 1 .... ____'~
" ~ , - L .... ~' ~ / '
.._ ' . ,./~ ~ / ~
' --.7- __.../'----==" "'"~--
0 28' SO' 1400'
CATELLUS DEVELOPMENT CORPORATION
C_~TEWAY BUSINESS P~RK Copl~ll, Texas
[--'~ ~ '-'.
- . ' .
.... ... ~ .........................
~TEL~S D~PME~ ~R~~
~TEWAY BU~N~ PARK ~!.
CATELLUS DEVELOPMENT CORPORATION ~L'£' "'"~m ,,o~z,~.. ~c ~
GATEWAY BUSINESS PARK Coppell. Texas