28 www. refrigerationandaircon. co. za RACA Journal I April 2026
REFURBISHMENT project
The third chapter began with a different philosophy. Rather than demolish everything and start anew, the VMG project team made a deliberate decision to reclaim and refurbish the original masonry plant rooms – correcting past mistakes while preserving what had been done right in 1986.
This approach required extensive stripping out. Old ducting, abandoned equipment, obsolete controls and redundant piping were removed, amounting to approximately 50 tons of scrap metal. Openings cut during the 2007 installation were sealed and waterproofed, restoring the integrity of the original plant rooms. Within these refurbished plant rooms, a modern VRF-based system was installed, complete with new refrigeration coils, electronic expansion valves, EC plug fan walls and controlled fresh air dampers linked to CO₂ levels in the store.
On the roof, 16 new LG Multi V5 VRF condensing units replaced the four large, packaged units, delivering roughly one megawatt of cooling capacity – significantly less installed capacity than before, yet far more effective. Protective wind barriers were also installed to enhance the corrosion-resistant construction of the new equipment, and to address the harsh coastal conditions that had plagued earlier systems.
The result is a system that finally aligned architecture, airflow and technology. What had once been an invisible problem was resolved through careful analysis, respect for the building’ s original design intent, and a willingness to reuse rather than discard.
The general condition of the corroded condenser coils due to the corrosive environment were removed.
Today, the store operates reliably and efficiently under conditions that had defeated previous installations. It stands as a rare example of how understanding a building’ s history – and learning from it – can lead to a solution that is both modern and enduring.
REFURBISHMENT OF A MASONRY HVAC PLANT The Ottery HVAC plant refurbishment commenced on 1 September 2025 and reached commissioning on 30 November 2025. The project involved the refurbishment of an existing masonry HVAC plant rather than a new installation or full replacement. It was a remarkable feat considering that it only took three months to complete, and provided the supermarket with a new, efficient and reliable air-conditioning system before the Christmas rush and holiday season.
Overall, the project benefited from a clearly defined scope and a well-developed design that had been carefully considered from the outset. Strong co-ordination between the client, consultant and contractor – Elmecair – meant that work on site progressed smoothly. Because there were minimal design changes during construction, the project avoided unnecessary stop-start cycles and rework, allowing activities to be properly sequenced and the programme to be maintained.
Early procurement of critical equipment, including coils, EC plug fans, electrical components and imported items, removed one of the most significant risks to the schedule. Confirming delivery dates in advance enabled realistic planning and reduced uncertainty. In addition, the close co-ordination of mechanical, electrical and architectural elements ensured that all layouts were clash-free, preventing delays during installation.
The experience and capability of the air-conditioning contractor played a major role in keeping the project on track. Elmecair’ s strong site management, quick resolution of issues and high level of supervision, helped maintain momentum and made the difference between meeting key milestones or missing them. Clear access routes, well-planned crane operations, and unobstructed plant room access further supported efficient material handling, rigging, decommissioning and installation works. Prompt decision-making and timely responses to queries and approvals also contributed positively to the programme.
Notwithstanding these advantages, the project was carried out within an operational store, which introduced challenges. The contractor had to work around restricted hours, noise limitations and access constraints, particularly for activities taking place on the trading floor. Even with these constraints, the project remained on schedule due to effective planning and co-ordination.
28 www. refrigerationandaircon. co. za RACA Journal I April 2026