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Gas Station QSR Build-Out — Vaughan

By Buildup Contracting

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Project type

Take-out quick-service restaurant built inside an operating gas station convenience store — a national QSR brand's kitchen, service window and drive-thru, with no dining room.

Location

Vaughan, Ontario.

Approximate scope

Four weeks of active construction for approximately $150,000. A full commercial cook line, walk-in cooler and dry storage, an order counter and illuminated service window opening into the convenience store, and a digital drive-thru menu board on the forecourt — all carved out of the back of a store that stayed open for business the entire time.

Completed quick-service kitchen line with beverage tower inside a Vaughan gas station convenience store
The finished kitchen on handover — cook line, beverage tower, and the service window opening back into the store.

Where we started

Not an empty shell. This was the back of an operating convenience store, with tiled walls, a working ceiling, live services, and customers on the other side of the hoarding. The first week was layout snapped onto the existing floor and selective demolition back to what could be reused.

Steel stud partition framing in the back-of-house during a Vaughan gas station QSR build-out
Steel stud framing for the kitchen enclosure, set off layout marked on the existing slab.

Scope of work

  • Layout of the equipment and partition grid on the existing slab, then selective demolition of tile, bulkheads and back-of-house partitions
  • Saw-cutting the slab for new sanitary and floor drain lines, then backfill and patching
  • Steel stud framing for the kitchen enclosure, service window wall and storage rooms
  • Electrical distribution, panels, conduit and device rough-in
  • Kitchen exhaust hood, make-up air and HVAC ductwork
  • Gas and copper domestic water rough-in
  • Cement board tile backer and drywall, taped and finished
  • Washable tile finishes through the kitchen and ware-washing areas
  • Walk-in cooler, dry storage shelving and back-of-house fit-out
  • Commercial equipment set, connected and commissioned — fryers, hoods, beverage tower, ice machine, three-compartment and hand sinks, kitchen display screens and POS
  • Order counter, brand graphics wall and stainless service window with illuminated menu boards
  • Drive-thru digital menu board — concrete footing, conduit and installation
  • Bollards, curb and site restoration on the forecourt

Building inside a store that never closed

The convenience store traded through the whole build, and that constrains almost every decision. Deliveries and debris move through a live retail floor. Noisy work gets scheduled around trading hours. The temporary wall between the site and the sales area has to be dust-tight and safe every single night, not just on inspection day. Several of the photos here show a finished kitchen wall with the store's shelving and till visible a few metres past it — that is the whole job in one frame.

Taped and finished white walls before kitchen equipment install in a Vaughan gas station QSR
Board, tape and finish complete, with the convenience store still trading on the other side of the wall.

The work under the slab

A cook line needs floor drains and sanitary lines that were never there. That means cutting into an existing slab inside an occupied building, laying the new runs, backfilling and patching — and getting it right the first time, because reopening the floor after the equipment is set costs weeks, not days. On this project the under-slab work was finished before framing started, which is what made a four-week schedule possible.

Saw-cut trench and new drain lines roughed in below the slab of an operating gas station store
New sanitary and drain lines laid in a saw-cut trench, then backfilled and patched.

Boxing in a commercial kitchen

Everything a QSR kitchen touches has to be washable, so the walls went up in cement board tile backer rather than standard drywall, with the exhaust ductwork boxed in as it ran back to the roof. Getting the hood, the make-up air and the ceiling line to agree inside a low existing ceiling is the tightest coordination on a job like this.

Cement board tile backer and boxed-in exhaust ductwork during a QSR kitchen build-out
Cement board tile backer, with the exhaust duct boxed in on its way back to the roof.
Stainless exhaust hood and fryer line installed in a Vaughan quick-service kitchen
Exhaust hood and fryer line set and connected under the finished ceiling.

The finished store

The customer never enters the kitchen. Orders are placed at the counter or the drive-thru, and food comes back through a stainless service window set into a graphics wall on the convenience store side — so the restaurant reads as its own storefront inside someone else's shop.

Stainless service window and illuminated menu boards at a gas station take-out restaurant in Vaughan
Stainless service window and illuminated menu boards facing the convenience store floor.
Finished order counter with POS terminals and kitchen display screens in a Vaughan gas station QSR
Order counter with POS terminals and kitchen display screens.
Brand graphics wall and menu board facing the convenience store retail floor
Graphics wall carrying the restaurant's identity into the store's own retail space.
Three-compartment sink and wire shelving in the ware-washing area of a gas station QSR
Ware-washing area — three-compartment sink, pre-rinse and wire shelving.
Walk-in cooler with wire shelving installed during a Vaughan gas station restaurant build-out
Walk-in cooler with shelving set, ready for stock.

The drive-thru

The forecourt work ran in parallel with the interior: a concrete footing and conduit for the digital menu board, then the board itself, bollards, and reinstatement of the curb and landscaping around it.

Digital drive-thru menu board installed on the forecourt of a Vaughan gas station
Digital drive-thru menu board on the forecourt, with the fuel canopy behind.

Timeline

Four weeks of active construction, from layout to a commissioned kitchen — with under-slab drainage, framing, mechanical rough-in, board, tile and equipment sequenced so no trade sat waiting on the one ahead of it, and so the store's trading hours were never the thing that stopped work.

Outcome

A complete quick-service kitchen, service window and drive-thru delivered in four weeks for about $150,000, inside a convenience store that never shut its doors. If you are a franchisee or a fuel retailer looking at putting a QSR brand into an existing site, that is the shape of the job: the cost sits in under-slab drainage, kitchen ventilation and brand-standard equipment, and the schedule sits on how early the floor gets opened and closed again.

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