This paper describes the bridge type selection process, preliminary and detailed design procedures, unique structural details and construction and steel erection for four complex curved single steel box girder bridges completed within the groundside component of the Terminal Development Project at Toronto Pearson International Airport for the Greater Toronto Airports Authority. The $4.4 billion project is scheduled for completion in three phases over a span of ten years, making it the largest single airport redevelopment project undertaken in Canada. The composite single steel box girder/concrete deck bridges are not commonly constructed in Canada. On this project, they were implemented for the single lane, high-speed ramps connecting the existing Highway system with the approach roads to the New Terminal One building. The single steel box girder bridge type was adopted as the optimal solution compared to other structure types, for specific locations. The governing criteria for type selection were complex geometry and deck width, feasibility, the need to maintain traffic under the bridges throughout construction, and limited space under the bridges to provide falsework supports. The number of spans varies between four and nine with the maximum spans up to 56 meters in length. Total length of bridges varies between 164 and 371 meters. Road geometry constraints resulted in minimum horizontal curve radius of 148.5 meters and maximum 6% grades. The unique details used in these bridges present an alternative, cost-effective approach in meeting each of the Client’s needs using innovative detailing and appropriate construction technology. The structures were tendered approximately 15% below the engineer’s estimates. The four bridges were completed in two construction contracts, between 2001 and 2003.
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