This major airport development project completely replaced an existing terminal with a larger, more efficient facility to accommodate more airline passengers at Canada’s busiest airport. The size and complexity of the project required the effort to be divided into phases. First came construction of the central processor, preceded by demolition of an existing facility. Next was construction of a concourse building and the Pier F hammerhead, both tied to the stage-one building. The facility holds 33 gates, and all services to aircraft and the buildings have been completely rebuilt — including 250,000 square meters (2.7 million sq. ft.) of apron.

With all work conducted in an operating airport, this project presented numerous unusual complexities. In addition to ensuring security was always intact, the client also required continuous operation of the old terminal for much of the construction schedule. In order to fulfill the client's requirements, PCL and partners introduced numerous innovations. These included a process for onsite disposal of 95% of the old terminal, creation of a temporary elevated road system for construction, temporary life-safety systems in a high-security environment, and processes for commissioning and smooth transition from one operating airport building to another. The work was performed over an eight-year period and now stands as one of Canada’s most successful and complex projects ever.