Shoprite Riverfields

The erection program for this project was challenging from the tender stage, with a tight schedule requiring the installation of 25 tons of steel per day, six days a week. The complexity was heightened by the need to work in six adjacent bays simultaneously, which posed logistical challenges for moving steel and equipment between bays. Despite these challenges, the B&T and Abbeydale teams collaborated effectively, with a friendly competition driving the steel erectors to catch up on the tilt-up columns. Their success was celebrated with a site braai, fostering strong relationships among the site staff. A key achievement was the erection team's ability to assemble the first four trusses in one go, saving significant time by minimizing work at height. However, the project faced a major challenge when new drawings introduced an additional 200 tons of steelwork for a gantry and dividing wall in the Freshmark building. This work had to be completed within 25 days and involved complex suspended steelwork from the roof. Although the original program had to be adjusted, resulting in a one-week delay at a critical stage, the dedication and teamwork of the main contractor, engineers, and erection teams ensured that the project was brought back on schedule.

The project faced several key challenges. A straight sloped roof was impractical due to the building’s width, leading to the design of a curved steel roof structure to minimize height while meeting racking requirements. The 242.3m arc length of the curved roof exceeded the maximum length for a single roof sheet, so vertical steps were introduced at third points along the width, allowing the roof to be split into three manageable sections. In the temperature-controlled Freshmark area, the roof had to support heavy refrigeration equipment and insulated panels. To keep the structure light yet effective, girder truss column spacing was reduced to 16m-24m, aligning with insulated walls. Additionally, a complex walkway and support structure was integrated into the design to accommodate the refrigeration equipment and piping. Installation challenges were managed through careful planning and teamwork, ensuring the project remained on schedule and met all structural requirements.