Cost of Getting into Rock Drilling

Considering a venture into rock drilling? Whether you’re taking on a drilling task that involves rock or need a solution for an unanticipated rocky job, it’s vital to understand that successful rock drilling goes beyond simply obtaining the right HDD rock bit. It requires comprehensive planning regarding the entire scope of requirements necessary to tackle hard ground conditions, along with a clear understanding of the expected expenditure on equipment. Recent searches indicate that the costs associated with entering the rock drilling industry can vary widely, driven by equipment choices, rental versus purchasing decisions, and overall operational necessities.

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A basic HDD set-up just won’t cut it

Utilizing a standard duckbill blade on your drill string while increasing your rig's power can lead to overwhelming frustration and potentially damage the HDD equipment. To drill through rock effectively, it's essential to invest in the acquisition or rental of hard rock directional drilling machinery.

Mud Motor (+ Drill Fluid)

A mud motor is crucial for rock drilling as it chisels away at rock surfaces, aided by a two-degree bend in its shaft for steering. Since this specialty equipment is integral, its cost carries a significant price tag. The high-impact nature of this task demands substantial amounts of drill fluid; for instance, while conventional drilling with a duckbill blade might use around 5-15 gallons per minute, even the smallest mud motor necessitates at least 40 gallons per minute. Here are some cost estimates:

• Mud Motor (Rent): $1,000-$3,000 per week

• Mud Motor (Buy): $14,000-$65,000

• Drill Fluid: (See end of article)

Rock Drilling Accessories Matter

Employing a mud motor also requires several essential ancillary hard rock directional drilling tools before you engage in any excavation.

High-flow housing

The substantial drill fluid required by the mud motor calls for a specialized high-flow transmitter housing. This housing not only protects your transmitter and drill string electronics but allows for an unrestricted flow of liquid, thereby optimizing operations.

• Cost to Buy: $3,000-$4,000

Drill fluid reclaimer

Given the volume of drill fluid necessary for rock drilling, it is economically impractical to use the fluid only once. A drill fluid reclaimer collects the cuttings, allowing for the cleaning and reuse of the drill fluid.

• Cost to Buy: $40,000-$300,000+

Tri-cone or PDC bit

Tricone or PDC bits provide specialized solutions capable of handling ultra-hard surfaces. Without such bits, your efforts at drilling rock may yield minimal progress, consuming valuable time and resources. These bits present a higher investment than standard options, but their efficiency is worth the cost.

• Cost to Buy (Used): $1,500-$4,000

• Cost to Buy (New): $4,000-$7,000

Hole-opener

We've mainly discussed the equipment needed for your pilot shot. If you're looking to create a hole larger than 4"-6", you'll require a specially-designed hole opener to back ream through solid rock. The price of a hole opener is approximately $1,000 per inch, meaning an 8" final hole will cost about $8,000.

• Cost to Buy: ~$1,000 per inch

More bentonite & additives

In addition to volume concerns, drilling rock necessitates increased additives to enhance the drill fluid’s viscosity. This adjustment is crucial to properly manage the weight of the cuttings generated during the process and prevent them from accumulating at the hole's base, which could impair performance and damage equipment.

Slower production and other hidden costs

Beyond the investments in hard rock directional drilling equipment and accessories, rock drilling inherently involves slower progress compared to soil drilling, leading to increased personnel costs due to extended job durations.

• Extra 1-2 workers for fluid mixing and reclaimer maintenance

• Increased time for handling cuttings disposal

• Cost for renting or purchasing a larger vacuum

• Additional operating hours incurred on equipment

• Increased equipment maintenance expenses

• Rising labor costs (due to longer tasks)

• Consultancy fees to assist inexperienced teams with planning and equipment usage

Comparison: Dirt vs. Rock Drilling Jobs

Wondering how rock drilling compares to standard jobs? Below is a comparison of production rates, tooling needs, and fluid costs when conducting a pilot shot in dirt versus rock:

• 100k drill rig (JT10, D100x140, etc.)

• 6-7" bit

• 600' shot

• Standard walk-over locator

• Reclaimer cost not factored

*Fluid required is measured in gallons

*Bentonite required is measured in pounds

Be prepared to face the realities of rock drilling projects. Larger budgets often come with significantly higher rock drilling costs, slower production rates, and an increased investment in HDD tooling and accessories that may reduce overall profitability. In cases even remotely linked to rock, it's wise to include a contingency clause in your bids or contracts for unexpected circumstances.

For more rock drilling tool information, please contact us. We will provide professional answers.

Approach your next rock drilling job with the right preparation from Melfred Borzall.

Despite inherent uncertainties in any HDD job, having the appropriate equipment and awareness of the task at hand can empower you to successfully finalize that rock drilling project efficiently and economically. Should you need further information about the best tools for rock drilling or any ground, our HDD specialists are eager to assist.