By the early 2000s, overcrowding at Toronto’s Union Station subway platform had become a major issue. With just one narrow island platform serving both the Yonge and University subway lines, the TTC launched a massive expansion project to improve passenger flow. The solution? Building a second platform for the Yonge line while upgrading the concourse and improving connections to Union Station and the PATH network.
When construction began in 2011, it was the largest concrete-cutting job commissioned in Canada—and Ontario Cutting & Coring was part of it.Solving Overcrowding at Canada’s Busiest Transit Hub
The Challenges
This was one of the most demanding and complex projects we’ve ever taken on. Even now, over a decade later, this project comes up in conversation around the office—because of its scale, complexity, and skill it required.
- Tight spaces & active transit operations – For 40 weeks, Our crew worked in a confined underground space extremely close to moving trains.
- Structural precision – We cut several large openings in seven-foot-thick concrete floor for the new 17-storey office tower being erected overhead.
- Massive concrete cutting & removal – We completed extensive cutting and waste removal–through thick slabs, ceilings, and structural beams to create the new platform. In total, we cut and removed 5.7 million pounds of concrete—all while the subway remained in operation. This had to
Our work
Ontario Cutting & Coring’s role was pivotal in making the new platform a reality. Our scope included:
- Removing walls, roof & central spline – Structural elements, including steel I-beam supports, were carefully cut and removed to clear space for the new platform. Among other things, this demanding project showcased the many advantages of diamond sawing: speed, versatility, lack of debris, low noise level, and the ability to cut very thick and/or reinforced concrete.
- Cutting 10 large caisson openings – We created a whopping 10 openings through seven feet of concrete to support the foundation of the new high-rise building above.
- Working in an active subway station – All work was executed with precision and safety, ensuring zero impact on daily transit operations or the project timeline.
The result
By executing one of the most complex concrete-cutting projects in Canadian history, Ontario Cutting & Coring played a critical role in modernizing Toronto’s busiest transit hub. The new platform significantly improved passenger flow and accessibility, shaping how millions of commuters move through the city every year.