When would a project need both a minor variance and site plan control approval in Ontario?

These two processes address different things, so it's genuinely common for a single project to need both. A minor variance is needed when the project doesn't comply with a specific numeric requirement in the zoning bylaw, such as a setback, height, or lot coverage limit. Site plan control, where it applies to the property, separately reviews the physical design details of the development, such as grading, landscaping, parking layout, and servicing, regardless of whether the project fits within the existing zoning requirements.

A project that fully complies with the zoning bylaw can still need site plan approval if it falls within an area or building type the municipality has designated for that review. Conversely, a project needing a minor variance for one specific requirement may also need site plan approval for the rest of its design details if it's the kind of development the municipality subjects to that process. Because the two approvals often need to be coordinated, with site plan details sometimes depending on what variance is actually granted, it's worth confirming early with the municipality's planning department whether both processes apply to your specific project, rather than assuming one approval covers everything.