September 29, 2026
AIL supplied the Ultra-Cor Buried Metal Bridge and MSE Precast Panel Walls used for the East Patterson Creek crossing, a significant component of the City of Vaughan, Ontario’s Kirby Road Extension. The major transportation project is creating a new east-west connection between Dufferin and Bathurst streets to support the city’s continued growth.
The buried metal bridge solution is designed for long service life, efficient material use, reduced maintenance and a lower carbon footprint compared with a conventional all-concrete structure. Skewed ends helped the structure to follow the watercourse and reduced steel costs.
Coordinated solutions for a complex site
The project presented a number of design and construction challenges. Ongoing changes to the road profile, grading and pathway required redesign of the headwalls, footing loads and wall layouts.
AIL worked closely with the consultant, contractor and rebar supplier to review revised drawings, verify site conditions and develop practical design solutions. These included layout revisions, rebar adjustments and coupler options.
Work began in May 2025 and continued even through winter conditions, with the project completed in August 2026. Close coordination, early design reviews and timely communication between all parties helped address changes quickly, minimize delays and control additional costs throughout construction.
AIL’s involvement in both the bridge and retaining wall components provided an integrated approach to the project, helping coordinate multiple structural elements as part of one infrastructure solution.
The project showcases how engineered structural plate and MSE wall systems can help deliver critical municipal infrastructure efficiently while responding to the complex demands of a large-scale urban expansion project.
