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Commercial | BROCCOLINI – ERIN MILLS TOWN CENTRE Around the World RENOVATING AND ADDING TO A 25-YEAR-OLD SHOPPING MALL WHILE IT REMAINED OPEN PRESENTED A SERIES OF CONSTRUCTION CHALLENGES FOR BROCCOLINI. BY RUSS GAGER mall’s second level will » The have a glass globe, which was manufactured in Germany. 88 CONSTRUCTION-TODAY.COM MARCH/APRIL 2015 D emolishing a 170-foot clock tower, building a glass globe 90 feet in diameter and replacing three huge skylight roofs with clerestories are just the beginning of the challenges Broccolini is facing in renovating 130,000 square feet of the Erin Mills Town Centre in Mississauga, Ontario. Renovating the enclosed shopping mall for its 25th anniversary and building a 25,000-square-foot addition to it while it remains open for business brings the total renovation and construction cost to around $100 million. The iconic centerpiece of the mall will be the glass globe, which is being mounted above the mall’s second level in its center where the clock tower had stood since the mall’s founding. Most of the globe will extend beyond the mall’s roof line and be as much of a landmark for the surrounding area as the clock tower that previously extended above the roof was. One of the challenges of building the globe – which is being manufactured in individual glass sheets by Gartner Steel and Glass in Germany – was where to put the tower crane while the mall remained open. “When we got the job designing the sequencing and logistics of the project, a big question mark was how we were going to demolish this giant clock tower and then build this giant ball right in the middle of the mall with no access,” Project Manager Cristian Yanez points out. “Everything that goes in that center court has to go through the interior mall or over it through the roof. We all decided a tower crane was the way to go, but where do we locate it?” During a site visit, Yanez had an inspiration. “I said, ‘Why don’t we stick the tower crane right in the middle of the mall adjacent to the clock tower?’” he recalls. “And that’s what we did. We built a giant concrete base next to the clock tower, and we dropped the tower crane right in the middle of the mall.” Many of the construction materials were lifted from the outside to the center of the mall by the tower crane. The globe will seemingly float 30 feet above an infinity pool on the first floor of the mall, but in actuality, it will be supported by 14 concealed brackets on a round truss system. “The main girders to support the truss weighed about 40,000 pounds each and were 90 feet long, and those were one piece of steel,” Yanez points out. “They were too heavy to pick up with the tower crane. So we basically just put them on a flatbed truck and drove them right through www.broccolini.com the mall.” Large • Construction cost: $100 million temporary ga• Location: Mississauga, Ontario rage doors were • Employees onsite at peak: 80 to 90 installed on the shift including subcontractors’ workers per mall’s first floor • Scope of work: Shopping mall renovat to allow large ion building materials and trucks to be transport- Cristian Yanez, project manager ed inside. Broccolini – Erin Mills Town Centre “We had to cut back about $6 million in less than a month.” 89 MARCH/APRIL 2015 CONSTRUCTION-TODAY.COM Commercial | BROCCOLINI – ERIN MILLS TOWN CENTRE » Most of the globe will extend beyond the mall’s roof line and be a landmark for the surrounding area. Removing Skylights Another massive undertaking was removing multiple skylights on the ceilings of three wings of the mall and over a food court, and rebuilding the roofs with clerestory windows. Unfortunately, each replacement took approximately seven months over the winter, and to meet the strict deadlines of the project, they had to be done at the same time. “So we selected a scaffolding company and built giant platforms across each of the entire wings of the mall,” Yanez relates. “We installed some temporary roofing and drainage to catch all the water and snow and then opened the roof right up.” With weather-tight seals above the scaffolding platforms – each of which measured approximately 30 feet wide by 300 feet long – the old roofs with the skylights were removed and the new clerestories constructed. Aluminum A-beam joists were used on the scaffolding so anchor points could be spaced up to 25 feet apart and openness maintained in the mall’s wings. The project’s approximately 20 subcontracting firms began working two shifts on 90 CONSTRUCTION-TODAY.COM MARCH/APRIL 2015 The Broccolini Way “For more than 60 years, Broccolini has built everything from homes to warehouses, to office buildings according to a particular belief: when you build great buildings, you also build great relationships,” the company says. “That is the Broccolini Way.” Founder Donato Broccolini’s first project was a single-family home in Montréal in 1949. “Construction in those days was very different,” the company says. “A handshake delivered and a word promised was considered more valuable than any signed contract. Donato understood this and strived to ensure that he always exceeded his clients’ expectations.” Over time, houses became residential streets and streets became entire neighborhoods. By building strong ties with clients and delivering quality work, Broccolini was well on its way to building a solid foundation for itself in Montréal, the company says. Over the following decades, the company grew. Residential neighborhoods turned into schools, churches and hospitals. In the 1980s, Donato recruited his three sons – John, Joseph and Paul – to support him in running the business. The four men saw the company move into new markets and build sophisticated retail outlets, manufacturing facilities and industrial complexes across Quebec. Broccolini also entered into the real estate industry. Over the years, the company purchased strategically placed land that became the sites for many of its projects. Today, three generations of Broccolinis run the business and guide its growth through Quebec and into Ontario. Supporting them is a team of more than 100 employees with experience in all kinds of disciplines: engineering, architecture, real estate, development and construction. promising the design of the mall. The architect wanted it one way, and we kept it that way.” This was accomplished through price negotiations, value-engineering and, in some cases, material substitutions. “We got the project back on track and budget, and when we did that, we were given the official contract,” Yanez says. the project in September 2013. Rerouting consumer traffic during construction was challenging. Some areas were completely walled off, while in other sections, enclosed walkways had to be built to provide access to stores. The renovation is scheduled for completion in November 2015. New Entrances Most of the new construction at the mall is for a glass-enclosed, 54-foothigh entrance and a second-level food court. The mall was designed by MMC Architects. “We’re redoing all the finishes, including drywall ceilings, new limestone floors and glass railings with stainless steel handrails,” Yanez says. The addition is structural steel with a slab-on-grade foundation and concrete slabs on the decks. Approximately 75 percent of the exterior is structural glass, and the rest is architectural block and stucco. The mall’s flat tar and gravel roof is being coated with a light concrete topping and a modified bitumen system placed over that. Broccolini has done many projects for the Erin Mills Town Centre’s manager, 20Vic Management, and was asked to examine the project before the fixed-price contract was completed. After the tender documents were drawn up and three to five different trades consulted, a final price for the project was calculated. “We had to cut back about $6 million in less than a month, and we did it,” Yanez recalls. “We basically didn’t change anything in terms of com- 91 MARCH/APRIL 2015 CONSTRUCTION-TODAY.COM