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November finish for Mall of Egypt concrete works

New 162,500m2 development due to open in September 2015

NEWS, Projects, Besix Orascom JV, Formwork, Mall of Egypt, RMD Kwikform

Concrete works at the new 162,500m2 Mall of Egypt is to complete by November 2014.

Set to be one of the world’s five star super malls, the project is being built by Besix Orascom JV, using formwork and shoring supplied by RMD Kwikform.

Due to open in September 2015, 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.

Located in the western half of the Cairo Metropolis and the 6th of October City, the Mall of Egypt is twinned with the Mall of the Emirates in Dubai, a project also worked on by RMD Kwikform.

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.

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.

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 signoff the more complicated elements of the project.”  

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