The Opry Mills Mall in Nashville is a 1.2 million SF mall originally built by Whiting-Turner in 2000. More recently, due to a flood, between two and 10 feet of water was in the mall and across its property. The mall stood as a stripped shell in need of reconstruction.
The rebuild effort included multiple flooring and ceiling elements. The flooring consisted of over 225,000 SF of ceramic tile, stone, carpet, wood flooring and refinished, colored concrete. The main street ceiling elements were a design-build effort and incorporated both traditional drywall construction and lightweight elements, such as stretch fabric and laminated beams. A new lighting design was installed throughout the mall and mechanical/electrical systems were repaired and refed. In addition, 90 tenant spaces, totaling 299,000 SF and 2,800 LF of tenant storefront, were built.
The project benefitted greatly from off-site construction techniques. Over 7,000 LF of bulkheads were framed in the subcontractor’s facility in Fredericksburg, Virginia and then shipped to Nashville for installation. Additionally, a drywall bending machine was used on site to prefabricate the drywall shapes needed to wrap the bulkhead framing, minimizing the drywall finishing required. The project was extremely successful, and it was delivered on time and under budget.