No Track Closures, No Problem: How EllisDon Delivered a Tunnel Under Live Rail

Most Metrolinx projects install pedestrian tunnels by closing tracks for a weekend, excavating, and lowering precast sections into place. But at Long Branch GO Station, a challenge presented itself where innovation was key.

With an active rail line, shale bedrock directly beneath the tracks, and limited access to the rail corridor, the project demanded a completely different approach.

EllisDon delivered one.

Using an innovative Petrucco Verona temporary bridge system and a cast‑and‑push tunnel installation technique, the team successfully installed a permanent, watertight tunnel while maintaining continuous GO Train service. 

Building Under Live Rail

To safely excavate beneath three active tracks, crews installed modular Petrucco steel bridges during two tightly orchestrated track closures. Supported by 36 micropiles, these temporary bridges carried full rail loads, enabling excavation to occur directly below.

EllisDon Civil self‑performed the excavation of 5,400 m³ of material, half of which was shale/rock repurposed for beneficial reuse. While working in a busy parking lot near residential areas, the team set up rigorous environmental safeguards. These measures featured ongoing noise, vibration and air quality monitoring, dust control, and the use of quieter machinery, all aimed at minimizing disruption to the local community.

"Constructing this tunnel beneath active rail using an innovative methodology is a true reflection of our team’s forward-thinking approach, dedication, collaboration” says Ricardo Pina, Construction Manager at EllisDon. “This milestone highlights our ability to tackle complex challenges with creative, engineering‑driven solutions on this uniquely demanding site. Saying I’m proud of what we’ve achieved together would be an understatement.”

Casting the Tunnel Beside the Tracks

To guarantee the time-sensitive and safe delivery of a high-quality structure, the team constructed the concrete tunnel adjacent to its final position. Complete with waterproofing, reinforcement, and a launching system, the structure was engineered for a precise lateral move beneath the tracks.

Moving a 477‑Tonne Structure Under Active Rail

Over two days, five 200‑tonne hydraulic jacks pushed a 477 tonne, 24-meter concrete tunnel structure beneath active rail lines, advancing in controlled 500 mm increments. Guide curbs ensured perfect alignment throughout the move.

Despite the complexity of the operation, GO Train service on the Lakeshore West line continued without interruption. 

A Safer, More Accessible Station

This installation marks a significant milestone for both EllisDon and Metrolinx. It showcases our ability to adapt global engineering techniques to local conditions while prioritizing safety, efficiency, and community impact.

The new tunnel will connect the future East Station Building to the platforms and surrounding neighbourhoods, improving access for Long Branch GO users and Alderwood residents.