When a major retailer like Tesco Metro prepares to open a new store, seamless logistics and efficient stock movement are paramount. At the new Tesco Metro unit on Chigwell High Road, the store’s layout required a critical structural modification: creating a precise opening within a raised section of heavily reinforced concrete to house a new scissor goods lift.
Here is how our team combined precision diamond drilling, track sawing, and robotic demolition to deliver the perfect opening on time and to specification.
The Challenge: Thick, Reinforced Concrete in Tight Quarters
The project required a large, rectangular opening to be formed out of an elevated, solid concrete plinth. Because the structure was deeply embedded with high-density steel rebar, traditional sledgehammers or standard jackhammers would have been highly inefficient, incredibly noisy, and structurally risky.
Furthermore, the opening had to be completely plumb and square to allow the new scissor lift to operate smoothly without any friction against the shaft walls.
Step 1: Precision Corner Stitch Drilling


To prevent over-cutting into the corners and to establish clean, structural boundaries, the Prime Cut team began by utilizing advanced diamond core drilling. By drilling precise holes at the corners of the intended opening, we created structural relief points that ensured the subsequent saw cuts would meet perfectly without damaging the surrounding floor.
Step 2: Track Sawing for Clean, Straight Edges


With the corner boundaries established, we mounted a Hilti 3-phase electric track saw directly onto the concrete face.
Track sawing is the ideal method for creating precise, straight, and deep cuts in reinforced concrete. Powered by a robust 3-phase electric system, the diamond blade sliced through both the aggregate and the heavy internal steel reinforcement mesh with ease, delivering a perfectly smooth finish along the perimeter of the future lift shaft.
Step 3: Controlled Demolition with the Brokk Robotic Breaker


Once the perimeter was cleanly isolated and cut, it was time to break down the internal concrete mass. For this, we deployed a Brokk remote-controlled demolition robot.
The Brokk allows our operators to stand at a safe distance while directing immense hydraulic breaking power exactly where it is needed. This method is incredibly efficient, significantly reduces Hand-Arm Vibration (HAVS) risks for our operatives, and rapidly broke the reinforced block into manageable debris.
As the concrete crumbled away under the power of the hydraulic breaker, the dense, internal grid of reinforcing steel rebar was exposed and systematically cut back.
The Finished Result



By combining three distinct, specialized disciplines—diamond drilling, track sawing, and robotic demolition—Prime Cut Diamond Drilling achieved a pristine, structurally sound opening tailored exactly to the dimensions required for the Tesco Metro scissor lift installation.
The edges were left perfectly straight, the structural integrity of the rest of the unit was fully preserved, and the site was left clean and ready for the next phase of fit-out works.
Whether it’s a high-street retail fit-out or a heavy civil engineering project, our investment in top-tier machinery like 3-phase electric track saws and Brokk robotics ensures we deliver:
- Unrivaled precision and clean finishes.
- Reduced noise, dust, and structural vibration.
- Enhanced on-site safety and rapid project turnaround times.
Do you have a complex concrete cutting or structural alteration project coming up? Contact the experts at Prime Cut Diamond Drilling today for a consultation.









