Mall Perforated Shutters – AQ Builders, Bahria Town Karachi

Project Overview

Millennium Roofing Systems (MRS) delivered a large-scale perforated shutter fabrication and installation project for AQ Builders at a commercial shopping mall in Bahria Town Karachi.
The objective was to manufacture and install 1,200 high-precision shutters within a tight six-month timeframe, ensuring security and aesthetic harmony across the mall’s retail façade.

To meet this demand, MRS established a complete on-site production setup, including:

• Shutter strip forming machine
• Perforation punching machine
• Sheet cutting machine
• Full welding station and precision hand tools

This end-to-end setup allowed seamless production directly at the site — reducing transport delays, improving quality control, and maintaining an accelerated workflow.

Client Challenges

The client faced two major challenges before MRS’s intervention:

• Compressed Project Timeline: The mall’s launch schedule required shutters to be ready and operational within six months.
• Need for Skilled Labour: The volume and precision of the perforation pattern demanded a highly trained fabrication team and specialized machinery.

Proposed Solution

To meet the client’s goals, MRS implemented a manual perforated shutter system optimized for speed, precision, and durability.

System Chosen: Manual Perforated Shutter
Material: AluZinc, 24-gauge
Design: Uniform perforation for light diffusion, ventilation, and visibility
Fabrication Process: Cutting, punching, welding, manufacturing, and on-site assembly
Installation Method: Modular system assembled directly on-site
Safety & Sustainability: All operations are conducted under strict safety standards with ergonomic handling and minimal waste

Execution Process

MRS deployed a mobile fabrication unit on the construction site, ensuring real-time coordination with civil and logistics teams.

Timeline: Completed within the 6-month schedule
Key Challenges:

• Each retail unit required shutters of different widths and heights, demanding recalibration of punching and forming machines per section
• Continuous coordination with civil works and transport logistics teams to synchronize shutter installation with ongoing mall construction

Workforce & Safety:
All site personnel were equipped with safety gear and supervised by MRS engineers to ensure consistent quality, production efficiency, and compliance with construction-site safety standards.