Mall of Egypt

Article Details

  • SYSTEM Shoring, Wall Formwork
  • PRODUCT GTX Beams, Rapidshor, Special Formwork, Superslim Soldiers
  • REGION Africa, MENA

Located in 6th of October district, Cairo, the new 165,000 sq m Mall of Egypt houses both retail and leisure facilities, including a state of the art ski park. RMD Kwikform has designed solutions for the construction of the ski park, including 80kN Rapidshor modular shoring with Superslim Soldier and GTX Beam decking; Superslim Soldier and GTX Beam wall formwork for the pile caps, shear and retaining walls; and independent Rapidshor stair towers for safe site access. In total, over 1,300 tonnes of equipment has been supplied for the project.

Currently being built by Besix Orascom JV using formwork and shoring supplied by RMD Kwikform, the new 162,500m² Mall of Egypt is set to be one of the world’s five star super malls.

The two storey structure will house both retail and leisure facilities, with 400 shops and 50 food and beverage outlets set to be joined by a state of the art Ski Park and provision for 6,500 car parking spaces.

Faced with a tight programme time and the need to overcome design challenges within the build, the Besix Orascom JV site team worked with RMD Kwikform designers in its Dubai office to create drawings and plans for the Ski Park part of the project. Critical to the planning phase was the identification of the right levels of equipment needed for the project, as Besix Orascom JV opted to purchase the complete solution.

A total of 1,300 tonnes of standard equipment was supplied for the project, sourced from across the Middle East region, including 80kN Rapidshor modular steel shoring with Superslim Soldiers and GTX Beams for the deck support. Additional Superslim Soldiers and GTX Beams were supplied for use in wall formwork applications for the pile caps, shear and retaining walls, with independent Rapidshor staircase towers providing safe access around the site.

For the construction of the 12.4m tall inverted pyramidal piers, which started at 2m by 2m and then grew to 4.3m by 4.3m, the engineering team designed a special corner arrangement, joined to the standard Superslim Soldiers. This solution allowed the piers to be constructed using standard RMD Kwikform wall form equipment.

On analysing the key challenge of casting the sloping slab and pyramidal piers for the Ski Park, RMD Kwikform engineers identified two design solutions to speed up the construction process. Instead of using timber wedges and steel supports to create the 12 degree slope of the Ski slope slab, the engineering team utilised the standard Rapidshor Tilt Head, traditionally used with the Rapidshor shoring system, which gave the exact slope support required. This not only ensured the right support for the 110m by 45.5m slab was provided, it also sped up the overall process, reducing erection time by 50%.

In order to support the erection, dismantling and safe use of equipment for the project, RMD Kwikform supplied a site assistance technician to work with the Besix Orascom JV site team. The technician provided practical product guidance to ensure safe working practices with the equipment supplied by RMD Kwikform. They also undertook pre-pour inspections, to ensure the equipment was erected correctly to the specification of the design drawing.

Commenting on this and the scale of the project, Mohamed El Gammal RMD Kwikform Regional Sales Manager – DBME said: “For a large scale project of this type it is all about safety, speed and simplicity. By working with the Besix Orascom JV team at the early stages of planning, we were able to identify and source the right amount of equipment needed for the project, in addition to engineering safe and timesaving solutions.

“On any project of this scale, we also recognise the benefit of providing onsite support and guidance, which in our experience dramatically improves efficiency and safety onsite. With this in mind, we supplied the project team with a site assistance technician, whose jobs it was to support the safe erection and dismantling of equipment. In addition, the engineer was also able to check and sign off the more complicated elements of the project.”

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