Lidl, Caerphilly

A mono-pitch roof featuring a Zambelli rib system on a timber truss structure was originally installed as part of a new build in 2007. The store was later extended and refurbished in 2013/14, incorporating new Alucobond wall cladding.

Over time, the store experienced persistent roof leaks, with the most significant issue affecting the shop floor. To address this, Central collaborated with Ash & Lacy to develop a tailored roofing specification. Multiple site visits were conducted before work commenced to determine the optimal system and methodology to meet the project requirements effectively.

The project was completed in two phases, beginning with the installation of an Ashzip roofing system over the existing structure, followed by the fitting of PPC Aluminium perimeter capping.

A site rolling operation was used to manufacture roofing sheets on-site, where metal was fed into a portable rolling machine and formed into the required panel shape and dimensions. Once formed, the sheets were lifted directly from the roller by a 60T crane and installed efficiently without touching the ground. The on-site roll forming maintained factory-quality production while eliminating transport and packaging costs, reducing waste, and saving time. By producing panels to the exact required length, material waste and excess packaging were avoided, and delays from delivery or unpacking were minimized.

All works were completed within two months while the building remained fully operational, even during the busy Christmas trading period, ensuring minimal disruption. Delivered on time and within budget, the refurbishment enhanced the store’s longevity, energy efficiency, weather resistance, and aesthetics, aligning with Lidl’s sustainability goals and providing a modern, functional, and eco-friendly retail environment.