North American Hard Rock Mine: 5‑Wing PDC Bit Achieves 687m Footage in F≤11 Abrasive Formations
Zero cutter failure · 38% higher ROP · Single‑run breakthrough in granite, basalt & dolomite
⛏️ Project Background: High‑Abrasivity Challenge in North America
In Q3 2024, a major North American mining company faced severe drilling efficiency bottlenecks at a hard rock mine in Nevada, USA. The formation consisted mainly of granite, basalt, and highly abrasive dolomite with rock hardness coefficient F ≤ 11. Conventional 3‑wing and 4‑wing PDC bits suffered from cutter chipping and rapid blade wear after only 300 meters, causing frequent tripping, project delays, and skyrocketing cost per meter.
- Granite / basalt / abrasive dolomite (F≤11)
- PDC bits lasted only 320m before failure
- 2+ bit changes per section, costly downtime
- Optimized for F≤11 hard & abrasive rock
- High impact resistance & extended life
- Minimize downtime, improve project ROI
✅ Solution: 5‑Wing Symmetric Reinforcement + Oil‑Grade Premium PDC Cutters
We recommended and custom‑engineered a 5‑wing oil‑field PDC bit specifically tailored to the mine’s formation and drilling parameters.
Bit Diameter
216mm (8½”)
Perfectly fits mine’s standard rigs
Thread Type
4½” REG
100% compatible with customer’s drill pipe
Cutter Technology
Oil‑grade premium PDC · Diamond layer +15% thickness
Abrasion‑optimized
Blade Structure
5‑wing symmetric reinforced design
Enhanced impact load capacity
End‑to‑End Customization Service
Customer only provided drill pipe thread drawing — we delivered the thread matching solution within 72 hours, manufactured the custom bit in 10 days, and shipped it via air freight directly to the Nevada mine site.
🚀 Field Performance: Stable, Long‑Lasting, Zero Failures
The bit was deployed directly into blasthole drilling operations with high‑pressure clean water circulation. Below is the actual customer‑reported data:
| Metric | Customer’s Previous Bit (4‑wing) | Our 5‑wing PDC Bit |
|---|---|---|
| Total Footage per Bit | 320 m | 687 m |
| Average ROP (m/hr) | 4.2 m/hr | 5.8 m/hr |
| Cutter Chipping / Blade Fracture | 2 events (2 bit changes) | 0 events |
| Hole Deviation | 0.8°/100m | 0.3°/100m |
This is our first time achieving over 600 meters per bit in granite formations. The stability of the 5‑wing design exceeded our expectations — almost no vibration throughout the entire section, and the hole wall is extremely clean. You guys really understand F≤11 hard rock drilling.
🧠 Technology Decoded: Why the 5‑Wing Excels in F≤11 Formations
Radial run‑off controlled within 0.2mm. Verticality improved by 60% in hard rocks like granite and basalt, drastically reducing hole deviation and drill string fatigue.
Custom‑thickened diamond table — +15% thickness. Impact toughness increased by 30%, cutter life in dolomite/limestone extended by more than 2x.
Large flow area nozzles — cuttings return rate increased by 40%. Eliminates bit balling and thermal micro‑cracking in high‑RPM hard rock drilling.
Diameters from 152mm to 311mm, all REG/NC/Z‑50 threads. Cutter layout adjustable for specific basalt/granite hardness.
📋 Proven Applications (Customer‑Validated)
⚠️
Not recommended for formations with F > 11 — for extremely hard strata, please consider our impregnated diamond bit series.
🔧 You Need This Efficiency Too?
Whether your project is in North America, South America, Australia, or Africa — if you are drilling in limestone, dolomite, basalt, granite, or other F≤11 hard & abrasive formations, our 5‑wing PDC bit delivers:
Simply provide your drill pipe specifications or a photo of the core sample. Our engineers will generate a custom solution within 24 hours.
- Send thread drawing / formation info
- 24h engineering proposal
- 10‑day manufacturing
- Global express delivery