JT4020 ALL TERRAINDIRECTIONAL DRILL

stopimg title="drillpipe_1" style="padding-right: 20px;" align="left" alt="drillpipe_1" src="/uploadedImages/Left_Nav/Press_Room/Job_Related_List/drillpipe_1stopimg4The Ditch Witch organization manufactures the most durable drill pipe in the underground construction industry. But even the most dependable pipe depends on you to use it properly. Yes, it's solid steel and manufactured with the utmost precision, but one false move—exceeding the pipe's bend radius, clamping on the body of the pipe, insufficient thread lubrication—and you can quickly ruin not only an individual pipe but also an entire drill string.

Pipe isn't cheap, as experienced horizontal directional drilling (HDD) professionals know well, nor is the downtime associated with replacing it, so it definitely pays to follow instructions in the operator's manual to the letter. Most HDD operators have learned how to execute a successful bore by making mistakes along the way. Sometimes experience is the best teacher, but by taking the following tips to heart, maybe you can avoid learning the hard way.

Before The Bore.

Proper drill pipe care starts long before you reach the jobsite. First, select a pipe designed for your drilling rig, keeping in mind that:

•  Simply selecting a tool joint that will function in the grippers is not enough. The tool joint must be designed to match the rig's output torque or it won't tighten correctly.
•  The outside diameter of the pipe greatly influences its steering characteristics. Too-large or too-small pipe bodies will not properly match the thrust and may create steering problems.

The bore should be thoroughly planned before unloading the rig. Take into consideration what buried hazards or obstacles exist on the jobsite (where and how deep they are), the size and type of material to be installed, the bend radius of the material and how deep it must be placed, your setup position and entry angle, and if the job allows entry and exit pits.

You'll want to use the lowest possible entry angle to minimize the bending necessary to drill horizontally at the proper depth; entry and exit pits help prevent sharp bends at these points, and allow the cutting tool to start without skidding and bending the pipe.

If you are using brand new pipe, perform the following preconditioning procedure three times for each pipe before first use:

      1. Hand-lubricate the entire surface of threads and shoulders of both ends of the pipe with the recommended copper-base tool-joint compound.
      2. Join the pipe and tighten the joint.
      3. Break the joint.

Failure to follow this procedure could result in fused joints and pipe damage. And remember to precondition new saver subs the same way you do new pipe.

During The Bore.

Both the drill pipe and the material to be installed have bend radius limits that you must know and never exceed. The maximum bend radius allowed for your Ditch Witch drill pipe is shown in a chart in your operator's manual. The product to be installed often has a bend radius different than the drill pipe, so the pilot bore should be planned for whichever has the greater bend radius.

How you make up and break apart tool joints greatly affects the life of your drill string. Before connecting drill pipe, lubricate the threads and shoulders of male joints with a copper-base tool-joint compound. This prevents rust and reduces wear on shoulders and threads. When necessary, clean the threads with high-pressure water and detergent. (Do NOT use gasoline or other petroleum-based solvents, as this will prevent the tool-joint compound from sticking to the joints and reduce thread life.)

Connecting and disconnecting joints should always be performed slowly and deliberately. Always carefully align the male and female ends of pipe before screwing them together. Poor alignment can damage the threads and destroy the usefulness of the joint.

stopimg title="drillpipe_2" style="padding-left: 20px;" align="right" alt="drillpipe_2" src="/uploadedImages/Left_Nav/Press_Room/Job_Related_List/drillpipe_2stopimg4Carefully time the rotation with the carriage travel speed. This will help prevent thread crossing, galling, and shoulder swelling. Tapered threads don't fully engage until the last 1/16 of an inch, so make sure the shoulder faces are touching and then tighten the joint with full machine torque.

Never rush the job by letting the ground finish making up the joint. This will not provide sufficient torque to make a good connection.

Of all the joints in a drill string, those just behind the drill bit take the highest stress. The lead pipe is in the ground longer, and gets more shockloads and rotation cycles. Use a transition sub between the tool and the first drill pipe to absorb shock.

Never use machine torque to make or break joints away from the machine. To break threaded joints away from the machine, first shut down the engine and then use a breakout wrench to perform the task. Clamp onto the drill pipe only in the designated areas; even small cuts in the pipe can quickly lead to fatigue during bending rotation. With a Ditch Witch EZ Connect tool, you don't have to break apart tight threads on downhole tools.

During the drill operation, never rotate the drill pipe without pushing or pulling, as this will increase stress damage at every bend. Likewise, don't push a full length of pipe in the drill frame without rotating, as this can cause pipe to buckle. Drill in half the pipe before pushing without rotation.

When guiding the bore, never exceed the bend radius for your pipe. Bending pipe more sharply than recommended will damage the pipe and cause failure. All steering corrections should be made as gradually as possible. Overcorrecting will cause "snaking," which can damage pipe and make drilling and pullback more difficult. It is important to begin straightening out of each correction as early as possible.

Excessive changes in pitch—the up or down angle of the bit and lead pipe—can bend the pipe just like oversteering does. In your operator's manual, the bend limits for Ditch Witch pipe are shown in a chart that provides the total deflection allowable in pitch or steering without damaging the pipe.

Because each pipe comes in contact with the saver sub, check it regularly for wear and replace it when it is worn, or it will damage the drill pipe. And always replace bits and backreamers as soon as they become worn, because dull tools put more strain on the drill string.

During Pullback.

Stresses on the product during pullback are transferred to the backreamer and drill pipe. When pulling in the product, be advised of the following:

• Do not pull the backreamer faster than it can cut.    
• Never backream without good fluid flow. The right mixture and flow reduce torque, thrust and pullback forces.
•  Use the smallest backreamer practical for pullback. If you need a large borehole, make more than one pass, each with a progressively larger reamer.

After The Bore.

When buying replacement pipe, always replace the entire string with pipe from the same manufacturer. The HDD industry has no established industry standard for threads, so not all threads are made equally. Parts from different manufacturers may appear to assemble, but this does not mean the joint was made up correctly.

stopimg title="drillpipe_3" style="padding-right: 20px;" align="left" alt="drillpipe_3" src="/uploadedImages/Left_Nav/Press_Room/Job_Related_List/drillpipe_3stopimg4Thread tolerances vary widely among manufacturers. And worn threads, of course, do not match any other threads. Mixing new and worn threads increases contact pressure and accelerates thread wear. Also, the bend radii of different brands of pipe may be different, which will cause accelerated and uneven wear on all pipe in the string.

Whenever you replace all of your drill pipe, replace the saver sub on the carriage, too. Putting new pipe through an old saver sub transfers damage from the sub to every new pipe in the string.

Because the lead drill pipe is in the ground longer, it is subjected to higher shock loads and experiences more wear. To help spread this wear evenly over all pipe, move the lead pipe to the last position in the rack after each job.

Drill Pipe Best Practices.

By making every effort to maximize the life of your drill pipe, you can help ensure the overall success of your HDD operations. Here's an abbreviated checklist to refer to when planning your next bore:

• Set up unit correctly. 
• Securely anchor drilling unit.    
• Break in threads on new pipe.    
• Make up and break out tool joints correctly.    
• Assemble and disassemble tool joints at moderate speed.    
• Keep the rotation speed and thrust speed synchronized. 
• Apply proper torque to all tool joints.    
• Avoid over-bending, over-steering and over-correcting.    
• Keep threads clean and lubricated.    
• Use correct drilling fluid for soil conditions and use plenty of it.    
• Refer to your operator's manual for complete drill pipe care, maintenance and operation.

stopimg title="19a" style="padding-right: 20px;" align="left" alt="19a" src="/uploadedImages/Left_Nav/Press_Room/Job_Related_List/19astopimg4Take the time to winterize your equipment this year. A few minutes spent could save you time and money in the months to come. The amount of winter care your equipment needs depends both on the climate and how it is used. Check your service manual guidelines, and keep the following tips in mind:

1. Check coolant. Provide protection by using the recommended antifreeze/water mixture for the lowest temperature expected during operations.

2. Change the oil and filter before cold weather arrives. In addition, use lubricants recommended for low temperature applications.

3. Maintain the battery. Remove cables, clean cable ends and posts, and clean and tighten terminals on the cranking motor. And remember never to charge a frozen battery.

4. Check tire inflation. Tires inflated in a warm shop will be under-inflated when used in cold temperatures.

5. Give hydraulic components time to warm up before beginning work. If you’re running diesel equipment, be sure to idle the engine a few minutes before shutting down to properly lubricate internal components. Your local Ditch Witch^® service technicians can help you make the most of your cold-weather equipment productivity, and can suggest winterizing techniques that are perfectly suited to your operation.

stopimg style="padding-right: 20px;" align="left" src="/uploadedImages/Left_Nav/Press_Room/Job_Related_List/boca1.jpg" alt="boca1" title="boca1" />Boca Enterprises, Hagerhill, Kentucky, has developed a reputation for completing difficult horizontal directional drilling (HDD) projects, often jobs that other contractors declined to attempt.

Boca owner Kirby Bowling recognized when he started his underground utility construction business in 1996 that the rocky soils of the rugged hill country of eastern Kentucky would be challenging, and that he should be prepared to excavate and bore in hard, rocky soil conditions.

"We do every kind of underground utility construction," said Bowling. "Gas, water, sewer, telephone, and cable television. In 2009, we did a lot of gas, but with stimulus money becoming available, we are doing more water and sewer in 2010."

As the company's business grew, Bowling began looking for a directional drilling machine that was relatively compact and could tackle the tough conditions his crews encountered on almost every job. He wanted an economical unit that could drill in rock without needing a mud motor and the high volumes of drilling fluids. Ideally the same machine also could operate in "normal" soil conditions.

stopimg style="padding-left: 20px;" align="right" src="/uploadedImages/Left_Nav/Press_Room/Job_Related_List/boca2.jpg" alt="boca2" title="boca2" />The solution was a Ditch Witch® JT2720 All Terrain (AT) machine Bowling purchased in 2001, and it has been the company's workhorse ever since.

The 27,000-pound pullback drill unit is equipped with the Ditch Witch organization's exclusive dual-pipe All Terrain drilling technology. The inner rod drives a rock bit while the outer pipe steers the downhole drilling tool for drilling pilot holes, and also provides rotary torque during backreaming. The mechanical drilling system delivers maximum downhole horsepower and operates on low volumes of drilling fluid. In addition to rock drilling, AT equipment is productive in almost every type of soil.

As Boca Enterprises grew, a new, larger, more powerful, rack-and-pinion JT4020 AT unit was added in 2009.

A recent project demonstrates the versatility of the All Terrain system.

An extension of water service in Knott County, Kentucky, required one segment of pipe to cross Carr Creek Lake near Hindman. The crossing would be 1,050 feet under the lake, which reached water depths of 45 feet, with the bore path being 20 to 25 feet below the floor of the lake.

Primary contractor G &W Construction, Morehead, Kentucky, selected Boca Enterprises to make the HDD crossing.

stopimg style="padding-right: 20px;" align="left" src="/uploadedImages/Left_Nav/Press_Room/Job_Related_List/boca3.jpg" alt="boca3" title="boca3" />To complicate the installation, surface features required the entry of the bore to be on the side of a mountain where a setup position for the drill unit was constructed. From the position of the entry point, the entry angle of the pilot hole was at a 50-percent downward grade, which then had to level off to proceed under the lake to the exit point on the opposite side.

The larger JT4020 AT was used on the project because its greater power provides the capabilities to pull longer runs of larger-diameter pipe than the smaller model.

The 1,000-plus-foot pilot bore was drilled with a 6.5-inch-diameter Sandvik Rotary Tools roller cone bit offered by the Ditch Witch organization. Subsurface conditions included sandstone and some limestone. Progress of the bore under the lake was tracked from a pontoon boat with a Ditch Witch Electronics 752 Tracker. A remote antenna was attached to the receiver to extend the antenna below the surface of the water and get closer to the beacon's signal.

The pilot hole was enlarged with 12- and 16-inch roller cone backreamers, and the length of 12-inch HDPE pipe was pulled back behind the 16-inch backreaming pass.

The JT4020 AT has 40,000 pounds of pullback, 5,000 foot-pounds of spindle torque, and spindle speeds to 250 rpm.

The JT2720 AT produces 27,000 pounds of pullback, 3,200 foot-pounds of spindle torque, and spindle speeds to 225 rpm.

Each of the self-contained models is mounted on tracks.

All Terrain technology enables both machines to drill in rock and other difficult conditions that are beyond the capabilities of other machines of comparable size and power ratings.

stopimg style="padding-left: 20px;" align="right" src="/uploadedImages/Left_Nav/Press_Room/Job_Related_List/boca4.jpg" alt="boca4" title="boca4" />Bowling said that during its first years of operation, Boca Enterprises served primarily as a specialist subcontractor, but has reached the point that it now bids jobs as the primary contractor. Over the years, the amount of directional drilling on projects has increased, and today about 80 percent of pipe and cable the company installs is with HDD.

Ditch Witch® equipment is manufactured by The Charles Machine Works, Inc., Perry, Oklahoma, a leading producer of underground construction equipment including trenchers, vibratory plows, horizontal directional drilling equipment, compact excavators, skid-steer loaders, excavator tool carriers, vacuum excavators, and related products.

stopimg style="padding-right: 20px;" align="left" src="/uploadedImages/Left_Nav/Press_Room/Job_Related_List/fluidmiser.jpg" alt="fluidmiser" title="fluidmiser" />Whether you're drilling in a new water line under a golf course club house, fiber optics under a highway, or utilities under a housing addition; Ditch Witch®lined drill pipe can help you get the job done with less fluid, less mess and less time.

You'll use less drilling fluid on the job because the Ditch Witch-exclusive, patented Fluid Miser®II lining functionally reduces the inside diameter of the pipe—and the amount of fluid it takes to fill the drill string—by up to 66 percent., The money you save from less water to haul, and purchasing fewer drilling fluid additives becomes significantover the life of that rack of pipe. And less drilling fluid means both less time to pressure up the drill string and less clean-up, saving you both time and money.

Fluid Miser II also works hard to shield the investment you have already made in drill pipe, downhole tools, and equipment because the lining actually protects the interior of the pipe, reducing rust scaling and extending the life of each joint of pipe. The reduced fluid volume not only minimizes the chance of high-volume mud plugging up nozzles in bits and backreamers, it also reduces the wear on your fluid pump, because it pumps significantly less fluid over time.

When you add up the savings on time, money and clean up, drilling with Ditch Witch lined drill pipe is a win-win-win situation.

stopimg style="padding-right: 20px;" align="left" src="/uploadedImages/Left_Nav/Press_Room/Job_Related_List/SlantBeaconHousing.jpg" alt="SlantBeaconHousing" title="SlantBeaconHousing" />Ditch Witch® downhole tools are engineered to be the most flexible in the industry. We believe this comes from their patented technology, their 50-year history of providing underground construction solutions, and the fact that Ditch Witch downhole tools are manufactured specifically for the drills with the same name on them. Simply put: they get the job done because they just fit better. All of these factors combined make them the longest-lasting, most ruggedly built tools in the horizontal directional drilling industry. Whether your project includes extreme soil conditions or the challenge of managing the spoils of long bores, here are several reasons why Ditch Witch downhole tools should be a vital part of your next drilling project.

stopimg style="padding-left: 20px;" align="right" src="/uploadedImages/Left_Nav/Press_Room/Job_Related_List/TalonBit.jpg" alt="TalonBit" title="TalonBit" />1. Ditch Witch beacon housings are several inches longer than most competitive housings, and the deflection angle on our bits is less aggressive by design. These two features combine to create exceptionally smooth steering, making steering corrections easier and lessening the chance of oversteering.

2. Aftermarket bits tend to be dramatically thicker, with carbide applied more generously. At first this may seem like a desirable feature. But Ditch Witch bits are engineered from the highest quality steel—so less steel is required to produce a bit of the same strength. And carbide is applied efficiently—only on the cutting edge, where it counts. The result is a more nimble bit that responds easily to steering corrections while still holding up the rigors encountered downhole. Compare this with heavier, bulky aftermarket bits, which some operators have described as trying to "push a brick with teeth" through the ground.

stopimg style="padding-right: 20px;" align="left" src="/uploadedImages/Left_Nav/Press_Room/Job_Related_List/Tracker.jpg" alt="Tracker" title="Tracker" />3. Some aftermarket manufacturers offer only bottom-load beacon housings. All Ditch Witch beacon housings are sideload by design. Our engineers know that the side of the housing (perpendicular to the steering) is the optimal location for the opening. Since most horizontal directional drilling steering is up and down rather than side-to-side, the majority of stresses encountered downhole are on the top and bottom of the housing. Placing the beacon opening at the highest stress point on the housing is not optimal. The tendency is for the housing to flex, causing the beacon door to come off, and the beacon to be lost. Ditch Witch sideload housings strategically place the beacon opening at their lowest stress point, protecting your electronics investment.

stopimg style="padding-left: 20px;" align="right" src="/uploadedImages/Left_Nav/Press_Room/Job_Related_List/TransitionSub.jpg" alt="TransitionSub" title="TransitionSub" />4. If your tracking electronics don't seem accurate, the problem could be your aftermarket housing. Because of the design of aftermarket bottom-load housings, it is almost impossible to place a Ditch Witch beacon in one so that the roll angle is properly clocked. Ditch Witch beacon housings and beacons are designed to work together to give you the most accurate locate on the market.

5. The beacon window on Ditch Witch housings is twice the size of the competitor's—so you get a stronger beacon signal, longer battery life, and a more productive bore. Additionally, the location of the beacon window on aftermarket housings causes inaccurate depth and right-to-left readings—up to eight inches off in some documented field reports.

stopimg style="padding-right: 20px;" align="left" src="/uploadedImages/Left_Nav/Press_Room/Job_Related_List/Beacon.jpg" alt="Beacon" title="Beacon" />6. The design of many aftermarket housings allows high-pressure fluid to cut into the beacon compartment, damaging the beacon. Ditch Witch housings utilize the drilling fluid flow to cool and protect sensitive electronics from the rigors experienced downhole.

7. Only Ditch Witch beacon housings come equipped with an exclusive Beacon Buddy feature that works two ways to protect your electronics: It not only accommodates a check valve to prevent nozzles from plugging; it also maintains fluid flow to prevent overheating if nozzles do become plugged.

8. The diameter of the ports and jets on competitive beacon housing are significantly smaller than that of Ditch Witch housings. When drilling fluid flow increases, the smaller diameter ports cannot handle the flow, increasing back-pressure all the way to the fluid pump and causing premature failure of pump seals and cups. The larger the pump capacity, the larger the problem. Other effects of this back-pressure include lugging of the engine, hydraulic overheating, and O-ring failure.

stopimg style="padding-left: 20px;" align="right" src="/uploadedImages/Left_Nav/Press_Room/Job_Related_List/Connector.jpg" alt="Connector" title="Connector" />9. The Ditch Witch organization uses the same propriety thread pattern on its saver subs, drill pipe, beacon housings, backreamers, connectors, and transition subs. This ensures the truest, tightest connection possible all the way through the drill string . . . for ultimate worry-free performance downhole. Other manufacturers try to match our thread pattern, but their connections aren't true, causing galling and cross-threading.

10. The pins on the competitive drill pipe do not match that of Ditch Witch drill pipe. This means that competitive pipe will not fully torque with Ditch Witch pipe at the shoulder and nose, nor will it bottom out in the box end. The types of failure this causes include mushrooming and splitting of the box end.

stopimg style="padding-right: 20px;" align="left" src="/uploadedImages/Left_Nav/Press_Room/Job_Related_List/radellConstruction_1.jpg" alt="radellConstruction_1" title="radellConstruction_1" />In business for more than 40 years, the owners of Kansas utility contractor Jim Radell Construction Inc. understand very well that the economy runs in cycles—sometimes very good, other times difficult.

"My father, Jim, started this company in 1968 to do telephone work," says Steve Radell, project manager of the family-owned business. "There was a downturn in the '80s, just when we had purchased some new trenching equipment, and the telecommunications industry's problems in 2000 and 2001 stopped much construction activity. Now we're in a worldwide recession."

However, Radell Construction is still going strong.

Providing consistently good service helped Jim Radell build and maintain a solid base of satisfied clients and expand into water and sewer projects, which has helped sustain the company during economic downturns.

"Our first customer was the primary service provider in our area, and we still are under contract with them," says Radell. "We were well established in 2000, and that helped us get through that period. There is a slowdown for us now, but we don't have much debt, so we're confident about the future."

Adopting new technologies to meet changing industry requirements also has helped Radell Construction not only sustain business in slow times but also grow.

Although Radell crews do some aerial splicing of fiber, copper, and coaxial communications cable, 90 percent of its work now is trenchless construction with horizontal directional drilling (HDD) and pipe bursting of clay, ductile iron and cast iron pipes.

Radell also has trenchers, conventional loader backhoes, and compact vibratory plows for those times when the most cost-effective construction options are excavating or plowing. For open-cut work, excavation equipment operated by the company includes two Ditch Witch® 115-horsepower RT115 models and three Ditch Witch 80-horsepower JT8020 units. The basic tractors accept interchangeable attachments, and the Radell equipment setup includes two disc trenchers, two vibratory plows, and one chain trencher.

Radell purchased its first horizontal directional drilling machine in the late 1980s, soon after the first utility directional drills came on the market.

stopimg style="padding-left: 20px;" align="right" src="/uploadedImages/Left_Nav/Press_Room/Job_Related_List/radellConstruction_2.jpg" alt="radellConstruction_2" title="radellConstruction_2" />"My dad was always looking for a better way to do things and was always looking for new technology," says Radell. "I grew up in this business, and I remember that first Ditch Witch drill had a separate power pack that was tethered to the drill unit, and it was not self-propelled. The controls were mounted on the carriage, and the operator walked back and forth as the carriage moved forward and backward. Horizontal directional drilling certainly has advanced since then."

Today the company operates three Ditch Witch horizontal directional drill models: a compact JT2020, a JT2720 All Terrain (AT) model, and a JT4020 AT unit, the largest in its directional drill fleet.

Because much of Radell's drilling projects are in rocky conditions, the company elected to purchase All Terrain equipment, which is equipped with a unique dual-drive drilling system that gives relatively compact horizontal directional drilling equipment the capability of drilling through rock and hard conditions that once required much larger machines as well as the use of a mud motor.

The AT design employs an inner rod to drive a rock bit, and the outer pipe steers the downhole tool for drilling pilot holes and provides rotary torque for the hole opener during backreaming. The mechanical drilling system delivers maximum downhole horsepower and operates on low volumes of drilling fluid.

"We considered the mud motor option, but decided the All Terrain equipment provided the easiest process for our needs," says Radell. "With a knowledgeable, patient operator, we find drilling through rock is just as easy as a normal bore. I certainly recommend this equipment."

In addition to rock drilling, AT models are productive in normal conditions and most other types of soil.

The JT4020 AT's rock-drilling capabilities were on full display during a recent project for Craw-Kan Telephone Cooperative. The assignment was to make a 1,650-foot crossing through solid limestone under the Neosho River near Erie, Kansas, for installation of a bundle of one 4-inch and two 2-inch diameter HDPE ducts that would hold both fiber and copper cables. "This was a complicated bore," says Radell. "From start to finish there was a 110-foot elevation change. We used a 6 1/2-inch TCI bit for the pilot hole. The pilot hole was surface-launched and exited in the flood plain across the river; it was 110 feet below the river at the deepest point. Two backreaming passes were made with a 12-inch TCI tool prior to pulling in the duct."

The project required 16 other bores ranging in length from 30 to 600 feet, with the average being 120 feet. Soil conditions included more limestone and clay. Most bores were for creek and street crossings. JT2020 Mach 1 and JT2720 All Terrain directional drills also were used on the project.

Craw-Kan has 33 exchanges providing more than 17,000 telephone access lines in Kansas, Missouri and Oklahoma. Other services include long-distance telephone, calling cards, dial-up Internet, cable television and digital television, and high-speed DSL Internet.

The JT4020 All Terrain has 40,000 pounds of pullback, 5,000 foot-pounds spindle torque, and spindle speeds to 250 rpm.

The JT2720 All Terrain produces 27,000 pounds of pullback, 3,200 foot-pounds of spindle torque, and spindle speeds to 225 rpm.

The JT2020 Mach 1 develops 20,000 pounds of pullback, 2,200 foot-pounds of rotary torque, and spindle speeds to 200 rpm.

Radell says the JT2020 and JT2720 AT are the most cost-effective construction options for installing telecommunication ducts. The larger JT4020 AT is used on telecom jobs when needed but has the power to pull in larger-diameter water and sewer pipes.

On most projects, Radell Construction is the primary contractor working on a turnkey basis. For water and sewer work, Radell crews place pipe, construct manholes, make connections, and make closed-circuit television inspections of the finished system. On water projects, services also are installed.

Although Jim Radell Construction serves a broad range of utility clients, telecommunications construction today is responsible for the largest percentage of Radell Construction's work, and a growing percentage of projects require trenchless methods.

Radell says that directional drilling is well accepted by most clients, and that most understand its benefits and the situations when it is the best option.

"However," he adds, "some engineers are still learning about the technology. We recently had a contract to replace an eight-inch sanitary sewer main that was specified as open-cut. But space was very tight, and a new parking lot was in place along the route of the pipe. We assured the engineer and project owner that we were capable of directional drilling on grade. After considering the circumstances, we got the go-ahead to do the on-grade bore and installed 400 feet of HDPE pipe. It saved time, money, and minimized surface disturbance and repairs."

Based in Pittsburg, Kanas, Radell Construction has 15 full-time employees, adding extra personnel when workloads require it. Most work is in Kansas, northern Oklahoma, and western Missouri.

Jim Radell still plays an active role in operations.

"I give my dad all the credit for the company's success," says Steve Radell. "He started the business from nothing and built it by insisting on doing quality work, making sure clients were always satisfied. He had the vision to see the future of directional drilling before most recognized its potential. He has set the standard we follow today. And he's still the first one at work in the morning and the last one to leave at the end of the day."

Ditch Witch equipment is manufactured in Perry, Oklahoma. In addition to directional drilling equipment, downhole tools, tracking systems, trenchers and attachments, the Ditch Witch product line includes vibratory plows, compact utility equipment, utility locators, vacuum excavators, and support products.

Ditch Witch products are sold and serviced by its worldwide dealer organization. Ditch Witch of Kansas, Valley Center, supports Jim Radell Construction.

stopimg title="JT3020_s_r_pace_1" style="padding-right: 20px;" align="left" alt="JT3020_s_r_pace_1" src="/uploadedImages/Left_Nav/Press_Room/Job_Related_List/JT3020_s_r_pace_1stopimg4Large contracting companies often call on specialist contractors to do specialized tasks on projects.

For underground utility construction, many contractors depend on horizontal directional drilling (HDD) subcontractors who have the expertise and equipment to make trenchless installations of conduit, pipe, and cable.

The arrangement works well for both primary and specialist contractors.

With specialist contractors who have proven to be reliable and do quality work, the primary contractor can turn over segments of projects to them and use subcontractors in peak periods rather than hiring additional workers and investing in equipment. For the subcontractor, it can mean steady work.

Most of the work of HDD specialist S&R Pace Pty Ltd, Sydney, Australia, is as a subcontractor for Infrastructure Construction, Sydney, which serves the primary electrical service provider in the Sydney area. Sydney, the state capital of New South Wales, is Australia's most populous city.

"With our agreement with Infrastructure Construction, about ninety percent of our work these days is making electrical installations," said Simon Pace, owner of S&R Pace. "However, we also have experience in telecommunications, water, and sewer construction."

stopimg title="JT3020_s_r_pace_2" style="padding-left: 20px;" align="right" alt="JT3020_s_r_pace_2" src="/uploadedImages/Left_Nav/Press_Room/Job_Related_List/JT3020_s_r_pace_2stopimg4Pace said his crew uses a 30,000-pound pullback Ditch Witch JT3020 All Terrain directional drilling unit to make installations ranging from 40 up to 190 meters in areas where trenching is impossible or impractical. The trenchless method of HDD allows cable and conduit to be placed under streets and highways, parking lots and other paved surfaces, landscaped areas, railroad tracks, streams and rivers, and environmentally sensitive locations.

A recent project involved the replacement of aging buried cable with new power cable in residential neighborhoods. Directional drilling is ideal in such conditions because installations can be made under streets, drives, lawns, and flower beds with minimal disturbance. In addition to replacing old cables, the upgrades provide increased service capabilities to the growing area.

The S&R Pace crew uses the drill unit to install HDPE conduit of various diameters, often in bundles of about 200mm that are installed in 500mm-diameter pilot holes. Pace estimates that about 75 percent of the company's drilling is in difficult, rocky conditions.

"When we started in business we had a drill unit made in Europe," he said. "But we had difficulty with drilling through rock so we went to the Ditch Witch All Terrain model. It is performing very well, and we're very happy with it. It gets the job done. We recently had a job to do a 250-meter river crossing through rock. We are very pleased with the All Terrain performance."

Most rock encountered is sandstone, Pace said.

The JT3020's All Terrain (AT) system allows the relatively compact machine to work through rock without the necessity to employ a mud motor and the high volumes of drilling fluid required by a mud motor to drive the cutting head.

stopimg title="JT3020_s_r_pace_3" style="padding-right: 20px;" align="left" alt="JT3020_s_r_pace_3" src="/uploadedImages/Left_Nav/Press_Room/Job_Related_List/JT3020_s_r_pace_3stopimg4AT technology employs a dual-drive drilling system with an inner rod to drive a rock bit. An outer pipe steers the downhole tool while drilling pilot holes and provides rotary torque for the hole opener during backreaming. The mechanical drilling system delivers maximum downhole horsepower and operates on low volumes of drilling fluid. The All Terrain system is effective for drilling through solid and broken rock, cobble, and gravel, and also can be used in all types of soil conditions.

In addition to 30,000 pounds of pullback, the track-mounted JT3020 AT develops 4,000 foot-pounds of torque, and spindle speeds to 225 rpm. Ditch Witch drill pipe and downhole tools are used for pilot holes and backreaming.

To mix drilling fluids, S&R Pace uses a Ditch Witch FM50 fluid mixing system mounted on a trailer.

The Australian Bureau of Agriculture and Resource Economics estimates there will be from $30 to $35 billion (Australian dollars) invested in the nation's energy infrastructure over the next two decades to accommodate growth. The amount includes base load and peak electricity generation, distribution and transmission systems; gas pipelines, and renewable plant. Electrical generation alone is expected to require $11 billion (Australian) of new investment.  

stopimg title="JT_1" style="padding-right: 20px;" align="left" alt="JT_1" src="/uploadedImages/Left_Nav/Press_Room/Job_Related_List/JT_1stopimg4Trenchless construction has changed the way the world's utility infrastructure is constructed and rehabilitated. While trenchless methods are perceived as a "new" development, a small number of trenchless pioneers have been using them for decades.

Back in 1982, Sweden's Styrud Ingenjörsfirma AB recognized the need for alternatives to conventional construction methods. The company adapted well-drilling equipment to drive pipe through the ground and designed and developed bits to use in the pipe-ramming process. In 1987, the company began investigating the then-new technology of horizontal directional drilling, and three years later invested in its first HDD machine.

The company now has its headquarters in Gothenburg, with regional offices in Malmö, Stockholm, Sundsvall and Karlstad.

Joint owner and Business Development Manager Rolf Borras says Styrud AB currently has 15 HDD units working in Sweden installing water and sewer lines, electric power and telecommunications cable, natural gas pipe, and piping for district heating and cooling systems.

Directional drilling is used in urban areas where excavation is difficult or impossible, on projects where surface improvements would require extensive and costly restoration, to install pipe and cable under highways and railroad tracks, and to bore beneath rivers, streams, and other bodies of water.

Styrud AB operates a wide range of Ditch Witch® directional drills, including the JT1720, JT2020, and JT8020 Mach 1, and the JT2720 and JT4020 All Terrain. The All Terrain models are designed to drill through rock and other difficult conditions without the need to use a mud motor. Styrud was the first organization to use All Terrain technology in Sweden.

All Terrain technology employs a dual-drive drilling system featuring an inner rod that drives a rock bit. The outer pipe steers the downhole tool while drilling pilot holes, and provides rotary torque for the hole opener during backreaming. The mechanical drilling system delivers maximum downhole horsepower and operates on low volumes of drilling fluid. In addition to rock drilling, an All Terrain unit is productive in nearly all types of soils.

stopimg title="JT_2" style="padding-left: 20px;" align="right" alt="JT_2" src="/uploadedImages/Left_Nav/Press_Room/Job_Related_List/JT_2stopimg4Styrud AB recently employed directional drilling to upgrade the district cooling network for Göteborg Energi, one of the largest energy suppliers in Sweden. Owned by the municipality of Göthenburg, Göteborg Energi provides electricity and gas for district heating and cooling for air conditioning. The purpose of the project was to enlarge cooling capacity and connect smaller systems that had in the past provided different parts of the city with cooling.

Styrud AB initially became involved on the project as a subcontractor providing drawings of plans and installing pipes. The company eventually assumed the position of general contractor, working closely with Göteborg personnel. Styrud AB now is involved in planning future segments of the improvement program.

"Because the entire extent of the ring main was located in the downtown area, trenchless technology was a natural first choice," said Borras.

The final part of the job was an 880-meter long section, consisting of two parallel pipelines 630 mm in diameter, from Pusterviksplatsen to Bältesspännarparken. The pipeline runs from there via Allén, Drottningtorget and St Eriksgatan to its end point at Lilla Bommen. Plans also call for the district cooling network to cross the river Göta älv on its way back to Rosenlund, as well as connecting the Lindholmen district to the ring main.

"Göteborg Energi is one of the organizations in Sweden that has invested the most in trenchless technology," said Görgen Johansson, Styrud AB project manager. "The presence of favorable geotechnical conditions is, of course, one of the explanations, but attention is also paid to finances, keeping in mind that trenchless technology is often more cost effective. The minimal level of environmental impact and the minimal disruption to traffic are also factors that carry a lot of weight."

During the project, Styrud AB used its Ditch Witch JT4020 All Terrain and JT8020 Mach 1 equipment. The company's crews completed 20 HDD installations ranging from 100 to 800 meters in length and two to 20 meters deep. The diameter of the installed HDPE pipe is 110 to 800 millimeters.

Johansson said Göteborg Energi is recognized as a progressive provider of energy and is on the leading edge for developing ways to use renewable energy. The company owns and operates several wind farms.

Styrud Ingenjörsfirma AB was founded in Herrljunga in western Sweden in 1978, and during its first years of business the company focused on the drilling of water wells. After adding its first trenchless capabilities four years later, the company's capabilities have steadily expanded. In 1989, Styrud AB completed its first project outside Sweden—a hammer drilling contract in the United Kingdom.

In 1996, the company added its first 40,000-pound drilling unit and the following year completed a difficult and challenging assignment in Romania to install a segment of a broadband cable just over 500 meters long under the Danube River.

Regional offices are located in Gothenburg and Sundsvall and to better serve Northern Sweden, the company purchased Järvsö Borr AB, a firm specializing in energy and water wells.

At the turn of the millennium, broadband expansion in Sweden was in full swing, and the company doubled in size in one year.

"In 2005 Styrud Ingenjörsfirma AB published its first manual on trenchless pipe installation," said Borras. "We also acquired Finnish Borealstar OY, with whom we had collaborated for several years, and which opened the door to the Finnish market, and an office was established in Helsingfors."

In 2007, TGB Borrteknik was acquired, making Styrud AB one of the major drilling companies in northern Europe. The main office, the western regional office, and StyrudTGB consolidated their premises in Sävedalen east of Gothenburg, while local offices in collaboration with StyrudTGB opened for business in Järfälla and Sundsvall.

To meet the needs of its clients, Styrud AB, operates drilling equipment in several size categories.

stopimg title="JT_3" style="padding-right: 20px;" align="left" alt="JT_3" src="/uploadedImages/Left_Nav/Press_Room/Job_Related_List/JT_3stopimg4The JT1720 develops 17,000 pounds of pullback, 1,800 foot pounds of spindle torque, and spindle rotation speeds to 200 rpm; the JT2020 produces 20,000 pounds pullback, 2,200 foot pounds of torque, and spindle speeds of 150 rpm; JT2720 equipment has 27,000 pounds of pullback, 3,200 foot pounds of spindle torque, and spindle speeds to 225 rpm. These compact models are well suited for construction sites with limited space for setup.

The two larger models are capable of installing larger-diameter pipes at longer distances. The JT4020 has 40,000 pounds of pullback, 5,000 foot pounds spindle torque, and spindle speeds to 250 rpm; the powerful JT8020 can produce 80,000 pounds of pullback, 10,000 foot pounds of torque, and spindle speeds to 210 rpm.

Each of the self-contained models is mounted on tracks.

Ditch Witch equipment is manufactured by The Charles Machine Works, Inc., Perry, Oklahoma, a leading manufacturer of underground utility construction equipment. The Ditch Witch product line includes trenchers, horizontal directional drilling systems, vibratory plows, vacuum excavators, compact skid-steer loaders, electrical utility locators, and related products.

Sales, parts, service, and product support for Styrud AB is provided by JLM Ditch Witch Scandinavia, Malmö, Sweden.

The Ditch Witch® organization manufactures one of the most extensive selections of horizontal directional drilling (HDD) equipment in the underground construction industry, from the small and maneuverable JT520 to the powerful, long-range JT8020. They are the only equipment manufacturer that also produces machines used to create the underground bores through which utility pipe is pulled.

"Being a manufacturer of HDD machines, we know the demands placed on drill pipe, the careful balance of strength and flexibility required to ensure maximum performance of the drill and the drill string," says Adam Hall, design engineer for the Ditch Witch organization. "Producing long-lasting drill pipe begins with the highest-quality steel and involves a precise, time-tested series of steps." Among these steps is a unique welding technique that does not produce stress concentration points common to other manufacturers' pipe. After welding, each pipe is inspected, and a piece of pipe from each batch is sectioned to ensure weld quality and integrity.

"We expect a lot from our drill pipe, so we put a lot into it," says Hall.

Ditch Witch drill pipe is considered by many to be the most durable, dependable and cost-effective pipe ever made for HDD applications. Designed to be compatible with most Ditch Witch HDD models, Ditch Witch Power Pipe® is made with a patented process using high-strength, low-alloy steel tubing that balances stiffness and flexibility, providing sufficient rigidity to maintain thrust during changes in direction. The pin and box are made from a different, extra-tough alloy pressed into and welded to the expanded ends of the tubing. "Our unique manufacturing process produces the straightest pipe in the business," says Hall. "Power Pipe's expanded, exceptionally strong ends are formed without the heat of forging process, leaving the integrity of the pipe intact and no strength reduction or the heat-affected zones."

Ditch Witch Power Pipe is also available with the company's exclusive Fluid Miser® II lining. With Fluid Miser II inside each joint of pipe, drilling fluid volume is reduced by as much as 60 percent, allowing the drill string to pressure up faster and clean up quicker, which saves time and money. Fluid Miser II lining also minimizes internal rust and reduces spillage during pipe breakout.

Ditch Witch All Terrain (AT) pipe is manufactured exclusively for the Ditch Witch All Terrain machines. The patented shaft-within-a-pipe design of All Terrain pipe features a strong drive rod that turns inside an outer pipe. This enables AT systems to transfer power to the cutting head more efficiently than any other system, and outperform all other rock-drilling systems in their horsepower class.

Designed for use with the Ditch Witch JT520, JT8020, and JT4020 AT HDD machines, UFE (upset forged end) drill pipe features an "upset" or thickened shaft wall at each end. The tubing ends of UFE pipe are subjected to high compression and heat in a forging die, causing the tube wall to increase and the tube outside diameter at the end to expand. Unlike one-piece forged pipe, Ditch Witch UFE pipe is a composite design with tubing and high-strength alloy ends, making the pipe and tool joints stronger and more resistant to abrasion. After forging, all Ditch Witch UFE pipes are fully heat-treated to eliminate any potential heat-affected zones. For more information about Ditch Witch drill pipe, please call 800-654-6481 or click here.  

stopimg style="padding-right: 20px;" align="left" src="/uploadedImages/Left_Nav/Press_Room/Job_Related_List/5a.jpg" alt="5a" style="width: 260px; height: 195px;" title="5a" />In the land down under, more and more underground utilities are being placed down under by horizontal directional drilling (HDD).

Infrastructure Constructions Pt. Ltd., Sydney, Australia, specializes in the installation of duct and cable for telecommunications and power and pipe for water and sewer systems.

“At least half of the work we complete these days is constructed using HDD,” says Peter Brown, business development manager, Infrastructure Constructions. “We own and operate four Ditch Witch® directional drilling machines, and it is rare that there is a day when one is not out on a job, and that's usually only when it is being serviced.”

Infrastructure Constructions® Ditch Witch equipment includes two 17,000-pound pullback JT1720 models, one 27,000-pound pullback JT2720 All Terrain, and one 40,000-pound pullback JT4020 unit, Ditch Witch 750 electronic trackers, and FM13 fluid mixing equipment.

Brown says the company is primary contractor for most projects.

Recent HDD projects include installation of 240 meters (approximately 787 feet) of 125-mm (5 inch) diameter HDPE pipe through solid rock for a low pressure sewer system and installation of multiple conduits for upgrading of an electrical distribution system.

Explains Brown: “The sewer installation was for Sydney Water, and we used the JT4020 with a mud motor and fluid recirculation system. This was a difficult installation due to several factors, beginning with the rock. The route was beside a major arterial road which snaked through a valley, and we had to keep within very narrow tolerances and maintain a negative fall. HDD was used because trenching would have caused major traffic disruptions.”

The electrical project was for Integral Energy, in the Kellyville area (Sydney’s northwest) and included multiple bores totaling approximately 2760 m (9055 feet). The JT4020 and JT2720 All Terrain and JT1720 equipment all were used on the project.

“Construction,” says Brown, “occurred mainly among residential properties, many with well-manicured lawns and stencil-crete driveways, so only minimal restoration was required. For that reason HDD completed 2690 of the 2760 m of conduit installed. Product varied from single-140-mm (51/2-inch) conduit to bundles of as many as eight-63-mm (21/2-inch) ducts. To install eight conduits would require a fairly large open trench. With HDD, only minimal reinstatement of entry and exit pits was necessary.”

Established in 1998, Infrastructure Constructions employs about 40 people and also uses subcontractors when appropriate. The company performs a wide range of utility construction, including trenching and non-destructive excavation, termination and testing of fiber-optic and copper cable, construction of manholes, technical advisory services, and project planning and management.

Brown says the company believes demand for underground construction services will increase over the next few years due to population growth and modernization of current underground infrastructure.

“Infrastructure Constructions is always striving to find more productive and cost effective ways of using HDD to benefit the customer,” Brown says. “Over the last 12 months, we have successfully completed a number of projects using HDD where trenchless technology originally wasn’t even considered.”

THE 420SX VIBRATORY PLOW CAN PLOW IN PRODUCT FASTER THAN ANY OTHER UNIT IN ITS CLASS.

stopimg title="49a" style="padding-right: 20px;" align="left" alt="49a" src="/uploadedImages/Left_Nav/Press_Room/Job_Related_List/49astopimg4The new Ditch Witch 420sx vibratory plow expands the company’s popular compact vibratory plow product offering and adds riding capability, greater horsepower (41 hp/30.5 kW), and several features that other vibratory plows in its class do not have.

The machine’s exclusive dual-speed attachment drive enables the operator to quickly adapt to changing ground conditions. The patent-pending plow design of the 420sx allows it to closely follow the contour of the ground, which helps the plow maintain a constant cover depth on uneven terrain. Besides a standard vibratory plow, the 420sx can also run a Roto Witch drilling attachment and a trencher.

“We’ve designed the head shaft of the trencher attachment to incorporate a large, heavy-duty auger,” says Brent Bolay, product manager for the 420sx. “The productivity and spoils handling of this attachment make the 420sx a true production trencher.”

As with other Ditch Witch products, the 420sx was designed with comfort and safety in mind. It is designed so the operator’s console moves with the operator when the machine’s frame articulates; the articulating joint is positioned under the floor of the operator’s station. The 420sx also minimizes vibration transmitted to the operator’s station, so the operator can work longer with greater comfort. The plow’s skid shoes keep plow pins and other components off the ground, which also saves wear and tear on the machine.

Another exclusive feature of the 420sx is the fold-down ROPS (roll-over protective structure), which enables the unit to operate under tree limbs, eaves, and other low-hanging obstacles. The fold-down ROPS reduces the unit’s overall height by 20 inches. This feature makes the 420sx highly maneuverable in and around jobsites.

PIERCE AIRROW II PIERCING TOOLS CAN TAKE A POUNDING—AND ARE, POUND FOR POUND, THE BEST OVERALL VALUE.

stopimg title="49c" style="padding-left: 20px;" align="right" alt="49c" src="/uploadedImages/Left_Nav/Press_Room/Job_Related_List/49cstopimg4New from the Ditch Witch organization are seven pneumatic piercing tools designed to perform short- to medium-range compaction boring projects, pipe ramming and pushing, and pipe pulling. The models range from 2.25" to 4.25" (57-108 mm) outside diameter, with or without threaded heads.

Strength and simplicity are the main characteristics that make Ditch Witch piercing tools so productive. Their bodies are made of single-piece, aircraft-quality steel, which contains high amounts of nickel and is heat-treated to be extremely durable. With fewer moving parts than the competition, Pierce Airrow II piercing tools are very low-maintenance units that promise years of reliable service.

Everything about these tools is designed for outstanding efficiency. Their unique striker design enables the tools to continue operation when they encounter a buried obstacle, so you can avoid costly downtime. The highly machined tool does not require wear rings that would require the tool to be disassembled more often for maintenance. These and other design features help Pierce Airrow II piercing tools give you more blows per minute than the competition—in some cases, as many as 100 more blows—so you can work faster and get more accomplished.

Utility companies, utility contractors, and municipalities will want to take advantage of the many benefits of these tools. Pierce Airrow II piercing tools are also ideal for Fiber-to-the-Home (FTTH) contractors looking for a fast, low-cost, trenchless solution.

THE NEW DITCH WITCH HT220 TRENCHER IS BIG ON SIZE AND ROCK-DIGGING POWER.

stopimg title="49b" style="padding-right: 20px;" align="left" alt="49b" src="/uploadedImages/Left_Nav/Press_Room/Job_Related_List/49bstopimg4The Ditch Witch line of trenchers just got bigger—a lot bigger. The HT220 is not the typical compact machine you’re used to seeing come out of the Ditch Witch factory in Perry, Oklahoma. But it still typifies everything you’ve come to expect from the Ditch Witch organization: quality, productivity, and extreme durability.

Optimized for digging in rock but also extremely effective in dirt, the HT220 is a hydrostatic trencher with 220 horsepower (164 kW). Designed for large installations—12 to 24 inches (305 - 610 mm) wide and 4 to 8 feet (1.2 - 2.4 m) deep—this machine has an exclusive flywheel gearbox that’s designed to deliver a tremendous amount of horsepower to the attachment—on demand—while protecting the hydraulic system and other components from shock loads. Plus, the operator vibration is further minimized by trencher stabilizers, standard on the machine, that isolate vibration when digging in rock.

Working in harsh conditions demands equipment that is extraordinarily durable and sturdy, and the HT220 does not disappoint. From the rugged undercarriage to the reliable analog controls to the forged, heat-treated, high-alloy steel head shafts that are guaranteed for life, everything on this machine is designed to endure the particularly rugged conditions of rock-laden jobsites.

Gas and oil, wind farms, rural water districts, and housing development contractors are just a few of the markets that will benefit from the HT220.

Published in the Spring 2007 issue of The Underground.

stopimg style="padding-right: 20px;" align="left" src="/uploadedImages/Left_Nav/Press_Room/Job_Related_List/41a.jpg" alt="41a" title="41a" />A long iron tube with threads on the end—how complicated can a piece of drill pipe be? The pipe itself isn’t, but selecting the right kind of drill pipe for your rig and the working conditions can be.

First and foremost, select a pipe designed for your horizontal directional drilling (HDD) unit. Simply selecting a tool joint that will function in the grippers is not enough. The tool joint must be designed to match the rig’s output torque or it will be improperly tightened. Also, the outside diameter of the pipe greatly influences the steering characteristics of the pipe. Too-large or too-small pipe bodies will not be properly matched to the thrust and may create steering problems.

Here are some other important considerations:

Is the pipe lined?
Lining was originally developed to deal with the corrosion caused by the drilling fluids available 15 years ago. Today’s fluids are less corrosive, but lining is still beneficial to the driller. It reduces the size of the cavity that fluid must fill every time a pipe is added to the drill string (lining reduces drilling fluid volume by as much as 65%). This reduces the amount of time required to pressure up a drill string and start drilling again. It also reduces the amount of mud spilled on the ground when pipes are removed from the drill string during pullback operations.

Will the welds hold?
Manufacturing practices play a big role in how a pipe performs. Forging can be used to produce a pipe with no weld seams, or to reinforce a friction weld. However, there is a limited amount of material that can be gathered to form the tool joint each time a pipe is heated. To gather large amounts of material on the end of a drill pipe usually requires several heating and forging cycles, which makes it difficult to produce a robust tool joint. Welding tool joints to a pipe body can produce a good pipe if the weld joint is properly designed. However, weld zones need to be structurally reinforced by stiffening the pipe in the weld zone. Increasing pipe diameter at the weld zone is the most effective method of reducing the working stress on the weld, and helps avoid failures in the weld or the heat-affected zone next to the weld. Pipe designs with unexpanded weld zones almost always fail prematurely in the weld zone, regardless of welding technique.

Is the pipe clean?
The heat associated with forging can cause “scale” to build inside the pipe. Scale is a hard, black layer of brittle iron oxide that is difficult to remove, but tends to pop loose when the pipe is bent. If a pipe is not aggressively cleaned after forging, the scale can come loose and plug the cutting tools, reducing mud flow into the bore. This can cause tracking beacons to overheat and possibly fail.

Do the thread patterns match?
When buying replacement pipe, always replace the entire string with pipe from the same manufacturer. The HDD industry has no established industry standard for threads, so not all threads are made equally. Parts from different manufacturers may appear to assemble, but this doesn’t mean the joint was made up correctly. Thread tolerances also vary widely among manufacturers. And worn threads, of course, do not match any other threads. Mixing new and worn threads increases contact pressure and accelerates thread wear. Also, bend radii of the pipe may be different, which will cause accelerated and uneven wear on all pipes in the string.

Published in the Fall 2007 issue of The Underground.

HDD contractors are running into tighter, more environmentally sensitive jobsites. Some of these sites also have older, hard-to-detect infrastructure that demands highly sophisticated guidance tools to minimize the possibility of damage. The Ditch Witch organization has responded to these demands—and many others—with these recent product innovations.

The JT922: A Sizeable Improvement
The JT922 is a powerful new directional drill that is more maneuverable, easier to operate, and easier to maintain than any other machine in its class. Featuring the highest power-to-size ratio in the 9,000-lb (40 kN) pullback category, the JT922 is a full foot shorter than its nearest competitor, making it easier to set up in tight spaces such as backyards and alleys, and also easier to transport.

"Our customers requested a directional drill that was easier to maneuver in tight spaces but still had plenty of power to do long bores," says the Ditch Witch organization's Richard Levings, senior product manager of HDD equipment. "We delivered with the JT922. It holds up to 300 feet of pipe—that's over 100 feet more than its nearest competitor—and the carriage travels the length of the drill frame in two seconds flat, for faster cycle times and more pipe in the ground. All in a more compact package."

The JT922 also meets customer demand for greater comfort. "The operator's station is midway down the drill frame and at a 90-degree angle to the rack, so it's easier to handle the pipe," he says. "And the seat slides fore and aft, so you can get closer to the pipe rack. It just makes everything easier on the operator."

The JT3020 Provides Quiet Efficiency
Building on the success of the popular Ditch Witch JT2720, the new JT3020Mach 1 is an extended-range, self-contained machine with 30,000 pounds (133 kN) of pullback. It can install product of up to 12 inches in diameter 500-800 feet in length, depending on soil conditions.

"It's everything our customers love about the JT2720 plus greater power, less noise, a better operator's station, and an incredibly efficient mud pump," says Levings. "The engine's new cooling design allows extraordinary horsepower (148 hp/110 kW) in a small, quiet package. Under normal operating conditions, the engine is quieter than some smaller HDD units. But the engine automatically turns up the torque when the drilling conditions become more challenging.

"The machine's fluid pump delivers 42-viscosity drilling fluid at 50 gallons per minute, helping the JT3020 drill with outstanding efficiency. The redesigned work station makes operators more efficient, too. "All of the information an operator needs during a bore, like pressure gauges and tracking information, is now right in his line of sight as he looks at the tool joint," explains Levings.

Dual-frequency Beacons Help Bypass Interference
When guiding a bore, HDD operators depend on their guidance system to avoid obstacles. But local interference can play havoc with signals transmitted by the underground beacons. Airborne signals transmitted by traffic loops, overhead power lines, airports, and even other nearby HDD crews can affect the signal, as can metal objects such as rebar, fences, nearby buildings, and underground facilities.

Having an alternate frequency to rely on is one way to keep your drilling operation on schedule. This is the benefit of the Ditch Witch organization's new dual frequency beacons, the 86BD and 86BHD. Offering 12 kHz and 29 kHz frequencies, these beacons reliably transmit roll angle, beacon temperature, beacon battery status, and pitch information. When interference disrupts the bore, the operator can switch the frequency of the beacon during drilling.

The 86BH and 86BHD generate signals that can be tracked to a depth of 50 or 70 feet, respectively.

Published in the Fall 2007 issue of The Underground.  

stopimg title="keepCool_img1" style="padding-right: 20px;" align="left" style="BORDER-BOTTOM: 0px solid; BORDER-LEFT: 0px solid; WIDTH: 260px; PADDING-RIGHT: 10px; HEIGHT: 195px; BORDER-TOP: 0px solid; align: left" alt="keepCool_img1" src="/uploadedImages/Left_Nav/Press_Room/Job_Related_List/1_KeepCool_260x195(1).jpg" border="0" />Catastrophic tornadoes and floods have grabbed recent headlines, but each year one weather phenomenon kills more people than tornadoes, floods, hurricanes, and lightning combined: heat.

According to the National Oceanic and Atmospheric Administration (NOAA), an average of more than 1,500 people in the U.S. die each year from excessive heat—yet it is the most preventable of weather-related deaths.

If you work in construction, summer is one of your busiest times of the year because it’s typically the driest season and offers the most hours of daylight. But the sun providing all that productive daylight can be the biggest jobsite hazard you face all year. No matter how tough you are or how used to the heat you think you are, excessive heat can bring down anyone who doesn’t take the necessary precautions.

The following information applies to anyone who is employed in an outdoor profession—construction workers in particular—but also applies to those who work in hot factories and anyone who spends time outdoors exercising, gardening, or laboring in any capacity during the summer months. (This is general information. More specific information can be found in the sources cited below.)

Know Your Chemistry

Our bodies dissipate heat by varying the rate and depth of blood circulation, and by expelling water through the skin and sweat glands. When we reach the danger zone, when our blood is heated above 98.6 degrees, we begin to pant—we’re literally “working like a dog.”

Sweating alone does little to cool the body, unless the sweat is removed by evaporation. But high relative humidity inhibits evaporation. When you’re checking the forecast for tomorrow, pay close attention to the heat index: the combination of relative humidity and air temperature. For example, if the air temperature is 96° F and the relative humidity is 65 percent, the heat index is 121° F. This is the heat your body really feels.

Heat disorders involve a reduction or collapse of our bodies’ ability to shed heat by circulatory changes and sweating, or a chemical (salt) imbalance caused by too much sweating. When heat gain exceeds the level the body can remove, or when the body cannot compensate for fluids and salt lost through perspiration, the temperature of the body's inner core begins to rise, bringing on various degrees of heat-related illnesses.

stopimg title="keepCool_img2" style="padding-left: 20px;" align="right" style="BORDER-BOTTOM: 0px solid; BORDER-LEFT: 0px solid; WIDTH: 260px; PADDING-RIGHT: 10px; HEIGHT: 195px; BORDER-TOP: 0px solid; align: right" alt="keepCool_img2" src="/uploadedImages/Left_Nav/Press_Room/Job_Related_List/2_KeepCool_260x195.jpg" border="0" />Ranking Heat Disorders

The severity of heat disorders is relative to a person’s age, weight, fitness, medical condition, and degree of acclimatization to the heat. For example, heat cramps in a 17-year-old may translate as heat exhaustion in someone who is 40, and heat stroke in a person over 60. Common heat disorders include:

• Sunburn. Along with being painful and irritating, sunburn can significantly retard the skin’s ability to shed excess heat. The best solution for sunburn is prevention, by applying sunscreen throughout the day.
• Heat cramps. Symptoms are painful spasms, usually in the muscles of the legs and abdomen, often preceded by profuse sweating.
• Heat rash. Also known as prickly heat, heat rash can occur in hot, humid environments where sweat is not easily removed from the surface of the skin by evaporation. Serious heat rash can be so uncomfortable that it inhibits sleep and impedes a worker’s performance.
• Heat exhaustion. Symptoms include heavy sweating, weakness, headache, fainting, vomiting, and skin that is cold, pale and clammy. It is possible to have a normal temperature with heat exhaustion.
• Heat stroke or sunstroke. This is the most serious health problem for workers in hot environments. Heat stroke occurs when sweating stops and the body can no longer rid itself of excess heat. Symptoms include an excessively high body temperature (106° F or higher); mental confusion or delirium; convulsions; hot, dry skin; strong and rapid pulse; and possible unconsciousness. Make no mistake: heat stroke can be fatal, and victims need immediate medical attention.

Prevention: The Best Solution

The number one method of avoiding heat disorders: avoiding heat. But for construction workers in the summer, this is simply not possible. So, here are some tips for staying cool and staying alive, beginning with the most obvious:

• Drink plenty of fluids. Your body needs water to keep cool. Drink water even if you don't feel thirsty. Proper hydration actually begins the day before a long, strenuous day in the sun. Before increasing your fluid consumption, consult a physician if you (1) have epilepsy or heart, kidney, or liver disease; (2) are on a fluid-restrictive diet; or (3) have a problem with fluid retention.
• Do not drink alcoholic beverages. Alcohol dehydrates your body. Enough said.
• Limit caffeine intake.
• Do not take salt tablets unless specified by a physician.
• Put less fuel on your inner fires. Foods that are heavy in protein increase metabolic heat production and also increase water loss.
• Dress as lightly as possible. You need protective clothing, of course, but consider light-colored fabrics, such as cotton, that breathe.
• When possible, take longer breaks than normal in a cool, shaded area. A rested worker is a more productive worker.
• Know the symptoms of heat illnesses. Use a buddy system to keep tabs on your fellow workers.
• Acclimate yourself to the heat. You can “get used to” the heat, to some degree. Workers, especially those who follow the advice above, can eventually develop some degree of tolerance. However, new employees and workers returning from an absence of two weeks or more should have a five-day period of acclimatization: 50 percent of the normal workload and time exposure the first day, gradually building up to 100 percent on the fifth day.

stopimg title="keepCool_img3" style="padding-left: 20px;" align="right" style="BORDER-BOTTOM: 0px solid; BORDER-LEFT: 0px solid; WIDTH: 260px; PADDING-LEFT: 10px; HEIGHT: 195px; BORDER-TOP: 0px solid; align: left" alt="keepCool_img3" src="/uploadedImages/Left_Nav/Press_Room/Job_Related_List/3_KeepCool_260x195.jpg" border="0" />Supervisor Obligations

There are precautions every employer should take when temperatures are high and the job involves physical work.

• Understand the signs of heat stress and permit workers to interrupt their work if they are extremely uncomfortable.
• Provide training about the hazards leading to heat stress and how to prevent them.
• If possible, schedule the heaviest workload for the coolest part of the day: early morning or late evening, when the sun is less intense.
• Make sure your workers have easy access to cool water—a minimum of one quart of water per hour, per worker.
• Schedule frequent rest periods with water breaks in shaded or air- conditioned areas.
• Routinely check on workers who are at risk of heat stress due to protective clothing and high temperature. Pay close attention to those who are at risk because of age and physical condition (including obesity and diabetes).

When A Fellow Worker Is Ill From The Heat

• Call a supervisor for help. If the supervisor is not available, call 911.
• Have someone stay with the worker until help arrives.
• Move the worker to a cooler/shaded area.
• Remove outer clothing.
• Fan and mist the worker with water; apply ice (ice bags or ice towels).
• Provide cool drinking water, if the worker is able to drink.

For more information about preventing and treating heat-related illness, consult these articles:

• “Heat Wave: A Major Summer Killer,” [http://www.noaawatch.gov/themes/heat.php] by the NOAA
• “Protecting Workers From Heat Stress,” [http://www.osha.gov/Publications/osha3154.pdf] by OSHA
• “Protecting Workers In Hot Environments,” [http://www.osha.gov/pls/oshaweb/owadisp.show_document?p_table=FACT_SHEETS&p_id=167] by OSHA

Sources for this article:

• National Oceanic and Atmospheric Association (noaawatch.gov)
• Occupational and Safety Health Administration (osha.gov)