The Challenge
As part of a retail store expansion in a megamall, the client required a vertical access point to connect their existing ground floor store to the newly acquired upper floor. This involved creating 2 new structural opening through a 360mm-thick reinforced concrete slab. Additionally, 4 embedded beams had to be cored to accommodate the anchoring system for a custom staircase structure. All works had to be finished within one-week and can only be performed overnight to avoid disrupting mall operations.
Our Approach & Result
We first scanned 4 beam points using Xradar™ to confirm reinforcement layout and safe coring paths. Then, using diamond floor saw for horizontal cuts and diamond wire saw for vertical cuts, we removed a 82 m² slab for the staircase opening and another 29 m² for void opening cleanly and without vibration. Stitch coring was carried out at the scanned beam locations to create secure anchor points for the new staircase structure. Despite the time and access constraints, the full job was completed in 11 nights along with the structural strengthening works around the beam and slab intersection, with zero disruption to mall operations.
A retail store expansion within a megamall needed to be completed with smart and precise engineering. The client needed a stairwell to connect their ground and upper floor units.
Our team was engaged to create a structural opening through a 360mm-thick slab while maintaining full integrity of the mall’s structure and adhering to strict nighttime work schedules. The work also included coring into structural beams to accommodate the new staircase system.
Before we cut, we scanned using Xradar™. We mapped 4 beam locations to identify safe zones and avoid compromising rebar or post-tension elements. Then, we marked out the 82m² staircase opening and the 29m² void opening for removal and used a combination of diamond floor saw and diamond wire saw to cut through the thickness efficiently.
We then stitch cored into 4 structural beams to accommodate a custom staircase anchoring system. At these locations, we cored to precise depth and alignment to allow the staircase to latch onto a newly installed I-beam, ensuring proper load transfer and long-term integrity.
To complete the works, we executed beam-slab intersection strengthening to accommodate the new opening and reinforced the surrounding slab areas. Despite the time limitations and the fact that all work had to be completed overnight, the full scope including cutting, coring, and strengthening, was completed within 11 nights, without disrupting mall operations.
