Construction World recently visited Fourways Mall where Concor is on track to complete the Fourways Main Roof Works Project by June. This fast track upgrade project started in October and forms part of the Fourways Mall Repositioning initiative and involves covering 50 000 m2 of the roof parking on level 7 with a roof, while 10 200 m2 of this will be fitted with solar photovoltaic (PV) structures. In addition, Concor was responsible for the rehabilitation of the access ring road. Martin Muller, Concor’s Contract Manager and Luke Matthews, the Site Agent, explain how this challenging project will future-proof Africa’s largest shopping mall.
Fourways Mall has a Gross Lettable Area of 178 000 m2, making it the biggest mall in Africa. It is currently repositioning itself with upgrades in functionality to ensure not only the structure’s sustainability, but its role as a regional mall. The Fourways Main Roof Works Project is one of these repositioning measures.
What makes the Fourways Main Roof Works project so significant is it size and the various logistical and technical challenges that Concor had to overcome. “The project spans 50 000 m2 and because we are working in a live retail environment, there are restrictions in terms of noise while the fact that the site is on the roof, places weight restrictions on the project,” says Muller. This fast track project is on track for its scheduled completion in June and reflects Concor’s ability to successfully perform projects in live retail environments.
The scope
“The project consists of the construction of concrete columns that support a steel roof over the existing rooftop parking on level seven. “This will provide covered parking to patrons while it will enable the future installation of a PV system,” Matthews explains. The roof will also mitigate previous water issues that the mall has been experiencing.
The scope includes a steel structure of 10 200 m2 that is being erected on the northeastern rooftop parking area. “Concor is providing the steel structure to support a PV installation that will assist with the mall’s sustainability and energy aspirations,” says Matthews.
Concor was also responsible for the rehabilitation of the mall’s access ring road. “This road could not be closed for an extended period as it provides access to a major retailer. It was therefore split into two portions. The first of this was reopened within two weeks to give access to this retailer. Concor had to remove old kerbs and road components, address construction and bridge joints, upgrade drainage, apply waterproofing and lay a final asphalt layer,” Matthews explains. Speed humps and road markings are being installed to ensure a good experience for mall visitors.
The rehabilitation of this 8 000 m² access ring road is key to the successful functioning of the mall by ensuring access of visitors to the mall. “The completed ramp from Witkoppen Road to Fourways Boulevard has already been opened to the public,” says Matthews.
Showing experience and expertise
Concor has a core of skilled and competent site managers, site agents and foremen that have acquired the skillset to work on and deliver complicated, fast track projects. “It is these expertise and experience that is brought to the project, as well as lessons learned on previous projects that enable us to offer cost savings to clients,” says Muller. “We are cognisant of the fact that the industry is under pressure currently, and there is a need to reduce cost wherever possible. This is taken into account during the project estimating portion, so that we can work in partnership with our clients to deliver a successful project,” he adds.
“Detailed construction management plans have been implemented to guide traffic and to ensure the safety of visitors,” says Muller.
On this project there are noise, weight and time restriction challenges that are mitigated because of Concor’s previous experience in the retail environment. “These are all overcome with a combination of innovation, expertise and experience,” says Muller.
The roof that will cover the parking area required the installation of 550 concrete columns, which range from 2,1 metre to 4,8 metre in height. “These columns will support a structural steel roof with sheeting while rainwater drainage systems are also being installed as part of the roof design,” says Matthews. The existing concrete surfaces had to be prepared before drilling and dowelling could start for the new columns. “Because existing columns from the original contractor had to be broken out, the noise factor and the need to stay on schedule with the casting of the columns, necessitated the need for a nightshift to be added,” he explains.
Using the mall’s current column structure means that the load of the new columns and roof structure are transferred safely through existing columns and beams down to the foundations.
“The initial plan was for the roof to have a physical curved structure which would have increased cost and weight. The roof structure, however, now makes use of straight trusses and it is adjusted to allow a sloped finish. When the sheeting is fitted, the roof will still maintain the planned curvature,” says Matthews.
The fact that this project is on the rooftop necessitated weight restrictions for both the final structure and during the construction phase. Muller explains that lightweight construction methods are being employed with the use of spider cranes and dumpers that are suitable for these restrictions. “Structural steel and readymix are delivered at street level and transported to the site via dumpers and trailers, which, while being cognisant of the weight restrictions, also minimise disruption to mall operations. The trailer that we use to transport structural steel from street level was specifically built for the project,” he says.
Lightweight Hebel bricks are being used to build walls around the lift lobbies. “These walls will interface with the structural steel and will be used for signage to ensure that visitors can orientate themselves when parking on the roof,” says Mathews.
The project has two on-site safety officers. “There are currently 105 people on site which includes those from Concor and the subcontractors. The subcontractors on this project are part of our daily toolbox meetings as daily planning and safety meetings are needed to prioritise health and safety on site as Concor is responsible for the overall safety of the site,” says Abiot Letshwene, the Construction Supervisor.
“This project displays Concor’s ability to execute large-scale and demanding projects in an active environment while balancing efficiency and safety with a quality result. At the same time, close partnership with the Fourways Mall team is ensuring the success of this project,” Muller concludes.