http://www.cic.gc.ca/english/information/pr-card/apply-urgent-processing.asp
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First, check your application's status online.
Based on its status:
If your application is already in process
Contact us through the case specific webform and follow the instructions for applying for urgent processing of your renewal/replacement permanent resident card. If you do not include a valid email address under Enquirer identification, we will not be able to contact you.
What happens next
If you send us all the information we ask for, including a valid email address, we will email you within two business days to tell you if we can speed up your application.
If you do not provide all of the information we ask for, we may not process your application urgently. We will continue to process it normally.
When your card is ready, we will usually mail it to you. In some cases, we may ask you to pick it up in-person at a local office.
If your application is not yet in process or does not appear in the system
Fill out another PR card application.
You must include all the supporting documents in this new application, including another set of pictures and certified copies of documents (if applicable).
With your application, include a photocopy of your proof of travel and proof of full payment for your travel.
The proof of travel, such as tickets or an itinerary, must show:
the dates you will be traveling,
your personal information including your full name,
that you have a return ticket leaving from Canada, and
your destination (where you are going).
The proof of payment must show that you paid for your ticket in full. It must show:
the date that you paid,
the full amount paid, and
how you paid.
If you do not send all this information, we may not process your application urgently. We will process it normally.
Please provide an email address where we can contact you if there are any questions.
Also include a photocopy of your receipt of payment form (IMM 5401) or electronic receipt for the application you previously submitted. Do not make a new payment.
On your envelope, write:
Urgent — Proof of travel included
What happens next: When we get your application, we will review it and decide if you qualify for urgent processing. When your card is ready, we will mail it to you. However, we may ask you to pick it up in-person at a local office.
If you do not receive your PR card before you have to travel, follow the steps for how you can return to Canada without a PR card.