Real-world drilling equipment success stories.

The challenge

A municipal water authority needed to install a 12-inch HDPE water main under a busy state highway without disrupting traffic. The bore path crossed through challenging mixed ground conditions including clay, sand, and glacial till with cobbles.

Equipment & materials

• 6" PDC pilot bit for initial bore
• 14" fly cutter reamer for pre-reaming
• 18" barrel reamer for final pullback
• Premium bentonite with PAC polymer
• HMW polymer for suspension in mixed ground
• Locating system for precise bore path tracking

The solution

The contractor worked with our Wausau location to develop a three-stage reaming approach. Starting with a 6" PDC pilot bit known for excellent steering in mixed formations, they established a precise bore path 18 feet below the highway. Pre-reaming with a 14" fly cutter addressed the cobble-laden sections, followed by an 18" barrel reamer for smooth pullback. Our fluid technician recommended a bentonite base with PAC for fluid loss control and HMW polymer for carrying capacity in the sandy zones.

Results & outcome

The 2,400-foot bore was completed in three days with zero traffic disruption. The multi-stage reaming approach prevented overloading the drill rig and ensured a clean borehole. Fluid returns remained excellent throughout, and the 12-inch pipe pulled back smoothly with no hang-ups. The highway remained fully open during the entire operation.

The challenge

A large dairy operation needed a high-capacity irrigation well to support crop production for 500+ acres. The well needed to penetrate 320 feet through sandstone and limestone formations to reach a productive aquifer while maintaining a straight, plumb hole for optimal pump efficiency.

Equipment & materials

• 12-1/4" TCI tricone for hard rock drilling
• 10" PDC bit for softer sandstone intervals
• Premium bentonite drilling fluid
• 12" steel casing to 80 feet
• 10" stainless steel well screen
• Gravel pack — #3 silica sand

The solution

Our Princeton team recommended a dual-bit approach: TCI tricone bits for the hard limestone layers and PDC bits for the softer sandstone intervals. This combination maximized penetration rate and bit life. We supplied premium bentonite for consistent fluid properties and recommended a high-efficiency gravel pack design with #3 silica sand matched to the aquifer grain size. The contractor set 12" steel casing through the overburden to 80 feet, then drilled open hole to 320 feet before installing 10" stainless screen in the production zone.

Results & outcome

The well was completed to 320 feet in five days of drilling. After development, the well tested at 850 GPM with just 45 feet of drawdown — exceeding the 800 GPM target. The straight, plumb hole allowed for efficient pump installation, and the properly-sized gravel pack prevents sand pumping. The dairy operation now has reliable high-capacity water for irrigation.

The challenge

A fiber optic installation contractor needed to safely locate existing underground utilities along 3 miles of urban streets before beginning HDD operations. The project area had aging utility records, and the contractor needed to verify depths and locations of gas, electric, water, and telecom lines to avoid costly strikes.

Equipment & materials

• Boss Vac trailer-mounted vacuum excavation system
• Potholing tools and hand digging equipment
• HDD support equipment for locating
• Bentonite drilling fluid for HDD installation
• PDC pilot bits and reamers for fiber conduit

The solution

Our Gun Barrel City office supplied a Boss Vac vacuum excavation system for non-destructive utility location. The contractor performed potholing every 300 feet along the proposed bore path and at all utility crossing points. Once utilities were accurately located and marked, they proceeded with HDD installation using our PDC pilot bits and premium drilling fluids. The vacuum excavation approach provided visual confirmation of utility locations and depths before drilling.

Results & outcome

Over 40 potholes were excavated safely in two weeks, revealing multiple utilities not shown on record drawings. The accurate utility mapping allowed the contractor to adjust bore paths and avoid conflicts. The fiber optic installation was completed with zero utility strikes — a critical success for the project. The Boss Vac system also proved valuable for exposing utilities during pullback operations when needed.

The challenge

A 2,000-acre farm implementing center-pivot irrigation needed six high-capacity wells drilled across two quarter sections. Each well needed to produce 400-500 GPM to support pivot systems. The geology varied across the property, with depths to productive aquifers ranging from 180 to 280 feet. Consistency in well performance was critical for uniform irrigation.

Equipment & materials

• 10" TCI tricone bits for hard sandstone
• 10" PDC bits for softer formations
• Milled-tooth tricones for overburden
• Premium bentonite and polymer drilling fluids
• 8" stainless steel well screens
• Gravel pack — formation-matched sizing

The solution

Our Chippewa Falls location provided a complete equipment package for all six wells and worked with the driller to develop a standardized completion design adaptable to varying depths. We recommended TCI tricone bits for hard rock penetration and PDC bits where applicable to optimize drilling speed. Each well received formation-matched gravel pack materials based on sieve analysis of cuttings. The standardized approach used 8" stainless screens and 10" boreholes across all wells for consistent hydraulic performance.

Results & outcome

All six wells were completed over an eight-week period. Production testing showed consistent performance: wells ranged from 420 to 540 GPM with similar specific capacities, indicating uniform well development. The standardized completion design simplified the process and ensured reliable performance across the well field. The farm now operates six center-pivot systems with dependable water supply for consistent irrigation throughout the growing season.

The challenge

An environmental consulting firm needed to install a network of 18 monitoring wells at a former industrial site to assess groundwater contamination. Wells ranged from 15 to 60 feet deep and needed to meet strict EPA standards for low-impact drilling to avoid spreading contamination. The wells needed to be installed through sandy soils with high water tables, coral rock layers, and limestone.

Equipment & materials

• 4" and 6" PDC bits for varied well diameters
• Rock bits for penetrating coral layers
• Clear water drilling (no bentonite for contamination concerns)
• Environmentally-acceptable polymer drilling fluids
• 2" and 4" PVC well screens and casing
• Filter pack sand — clean silica sand in multiple grades

The solution

Our Vero Beach office, with HDD specialist Kurtis Fulkman, worked closely with the environmental driller to supply equipment meeting EPA low-impact drilling guidelines. PDC bits provided efficient drilling in sandy soils and limestone, while rock bits handled the coral layers. Instead of bentonite, we recommended environmentally-acceptable polymer fluids that would not interfere with groundwater sampling. Each well was completed with PVC casing and screen, with filter pack sand sized to the formation. All materials were pre-cleaned to prevent introduction of contaminants.

Results & outcome

All 18 monitoring wells were installed over three weeks following EPA protocols. The wells showed excellent hydraulic communication with surrounding formations and provided clear water samples for laboratory analysis. Low-impact drilling techniques prevented cross-contamination between zones. The well network successfully provided the data needed for site characterization and remediation planning. The contractor noted the quality of the PDC bits and filter pack materials throughout the project.