Regular inspection and maintenance are essential to success on any horizontal directional drilling (HDD) job. While most crews stay on top of maintaining their drill rig and support equipment, the HDD tooling downhole deserves just as much attention. Tooling that’s properly serviced, inspected, and replaced when needed not only performs better but also helps prevent costly downtime.

What Affects HDD Tooling Lifespan

There’s no set service interval for HDD tooling. Its lifespan depends on a range of factors - ground conditions, operator technique, bore steering requirements, and drilling fluid use all play major roles.

Most contractors know rocky formations can be tough on tooling, but abrasive materials like sand can be just as damaging. For example, sandy loam is usually ideal for drilling, yet without proper lubrication from the right drilling fluid mix, tooling can wear out prematurely. Even in favorable ground conditions, drilling fluids are necessary to reduce friction and prevent wear on bits, reamers, housings, and rods.

Operator control is another big factor. Oversteering or trying to push the bore faster than the conditions allow can cause stress on the tooling and shorten its life. A skilled operator who stays within the limits of the ground conditions can make tooling last much longer.

How to Inspect HDD Tooling

To keep tooling in good working order, inspect each piece attached to the drill string both before and after every bore.

• Thread Care: Apply grease to all threaded connections when adding new tooling. Check thread integrity with a thread gauge to prevent connection failure.
• Monitor Performance: Stay alert to changes in torque or steering during a bore - these can signal worn or damaged tooling.
• Visual Inspection: Look for cracks, thinning, missing components, or loss of productivity. Some tooling can be rebuilt, but eventually, every piece will reach the end of its service life.
  
  

Inspection guidelines for common HDD tooling components

Starter Rod Inspection

Inspect the collar for signs of wear that could compromise torque handling. Check behind the collar for debris buildup that can narrow the rod and create “hourglassing.” If significant hourglassing is found, it’s time to replace the starter rod.

Proper alignment is also key. After tightening and loosening to align the flats, make sure the connection gap is no more than 1/16 inch (1.6 mm). Any larger gap can lead to flexing, cracking, and early failure.

Find Starter Rods here: HDD Starter Rods available at Georgia Underground

Transmitter Housing Inspection

Inspect the fluid ports, bolts, and lid for damage or blockages. Measure the outside diameter - if it’s worn down by 1/8 inch or more, replacement is likely due.

Check the threads on the backend and replace the spud if it shows wear or cracking. Look inside the sonde compartment for any cracks or signs of fatigue that could worsen with use.

On most models, only the hardware, lid, water nozzles, and spud adapter can be replaced. If cracks or heavy wear are found, replace the entire housing to prevent equipment failure.

Find Transmitter Housings here: HDD Sonde Housings available at Georgia Underground

Drill Bit Inspection

Examine the bit’s integrity, shape, and carbide buttons. Look for cracks or deformation that could affect performance. If the carbide buttons have worn down so they look more like fingers than buttons, it’s time to replace the bit.

Check for wash around the carbide areas and ensure there’s enough diameter left to cut efficiently and maintain steering control. Finally, verify the torque on bit bolts to keep the drill string secure and reliable.

Find Drill Bits here: HDD Paddle Bits at GUS

Reamer Inspection

Inspect thread condition and replace damaged spuds or adapters. Check that cutters, whether shark or rotary, are in good condition and that there’s still adequate hardfacing.

A reamer has reached the end of its life when the casting or teeth are excessively worn and the body’s integrity is compromised. Keep ports clean, maintain a solid hardface, and ensure proper flushing to get the most life from the reamer.

Find Reamers here: HDD Reamers and Hole Openers available at GUS

The Bottom Line

Extending the life of HDD tooling requires consistent inspection, proper maintenance, and timely replacement. By paying attention to wear patterns and adjusting for ground conditions, contractors can avoid unnecessary downtime and protect their investment in quality tooling.

HDD Solutions from Georgia Underground Superstore

At Georgia Underground Superstore (GUS), we understand the demands of HDD work and the importance of dependable tooling. That’s why we supply high-quality HDD tooling, parts, and equipment from the industry’s leading brands, all backed by our expert service and support. Whether you need replacement bits, reamers, or complete tooling packages, GUS has the inventory, experience, and product knowledge to keep your crews drilling efficiently and safely. Visit us in-store or online to find the right solutions for your next HDD project.

Find all HDD tooling, parts, equipment, batteries, and fluids here: HDD/Horizontal Directional Drilling Products for Utilities

Find Your HDD Salesperson

Texas

Mike Bearden - mbearden@georgiaunderground.com

Jessy Mendez - jmendez@georgiaunderground.com

Oklahoma

Tim Allendorf - tallendorf@georgiaunderground.com 

Georgia

Keven Hyatt - khyatt@georgiaunderground.com