Abstract Manager

 Background: Upgrading buried fire protection infrastructure within an active rail yard requires balancing asset renewal and operational continuity under significant physical and logistical constraints. At the Willowbrook Rail Maintenance Facility in Toronto—one of GO Transit’s most critical operational assets—the existing firemain network, which is a dedicated system of pipes supplying water for firefighting purposes, extends nearly 3 km and is over 40 years old. Over time, the facility experienced increasing pipe failures which required full network replacement.

 Key Issues: The network had limited redundancy , existing utility congestion, and a live-track work environment. These challenges not only created unacceptable operational and safety risks, but also increased the likelihood of service interruptions and compromised emergency response capabilities, emphasizing the need for immediate action through a comprehensive system replacement strategy.

Key Objectives:
This presentation outlines a risk-driven approach to feasibility, constructability, and preliminary design for the Willowbrook Yard Firemain Replacement project, developed with a focus on active rail operations and asset management priorities.

Methodology: The design process included; subsurface utility engineering (SUE), geotechnical and environmental investigations, which assess ground conditions and environmental impacts; and hydraulic modeling, a process that simulates water flow and pressure throughout the network. A full-scale fire flow demonstration—a live test to verify the system’s ability to deliver adequate water for firefighting—was also conducted with Toronto Fire Services. These steps enabled informed decisions on alignment selection, system redundancy, and construction methods, all while minimizing operational disruptions.

Multiple alignment options were evaluated based on how they would affect rail operations, maintainability, and constructability risk. The preferred solution is a perimeter-based, looped firemain system approximately 2.75 km long. This system will be installed using both open-cut and trenchless methods, to reduce conflicts with active tracks and critical facilities. Key risk mitigation measures include municipal connection redundancy, enhanced valve isolation spacing, using corrosion-resistant pipes suitable for contaminated soils, and phasing construction to maintain continuous fire protection.

Conclusion: These risk mitigation strategies ensure that the fire protection system remains reliable and operational even during construction or unexpected disruptions, thereby safeguarding both personnel and critical infrastructure. The project demonstrates how proactive asset management, early risk identification, and constructability-led design can extend system reliability and reduce operational risk in complex rail environments.

 Attendee takeaway: Attendees will gain practical insight into managing fire protection, construction, and asset risks when renewing underground infrastructure within live rail facilities.