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SURFACE DRILLING

Blasthole bounty Full computerisation in DTH drilling, drill cutting analysis while drilling and much more. John Chadwick finds it has been an exciting recent few months for important breakthroughs

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erhaps the most exciting news in surface drilling for some time came from Atlas Copco at the Bauma exhibition in Munich in April where it announced a major breakthrough in drill cutting analysis; a new scanning device which enables ore content to be constantly measured while drilling. The result from the online analysis will be provided as a digital block model, giving a clear view of the orebody. The scanner will be available for most Atlas Copco drilling equipment. The system reduces lead times for analyses as there is no need to prepare samples. It should improve sampling accuracy; give detailed ore grade and location information and cut sampling costs. In addition, the ability to scan while drilling will enable mines to optimise downstream extractions and mineral processing thanks to the detailed orebody block models that can be produced. The system is a result of co-operation between Atlas Copco Rock Drills and IMA Engineering. IMA’s Jukka Raatikainen told IM: “This launch will start with a concept based on an integrated technology combining drilling, sampling, and analysis with 3D blast and loading maps design almost in real time.” In his opinion, and that of many looking at this concept, it “covers the most critical part of mining,” and the economic results from using the system could “be close to being a revolution in mining.” In more Atlas Copco news, down-the-hole drilling has taken a significant step forward with the launch of a fully computerised drill

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rig. It says that for more than 10 years its ROC L8 drill rig has “been the most successful DTH crawler in open pits around the world – largely due to its robust construction, high performance and proven reliability. “Now miners can combine the advantages of the ROC L8 with those of the SmartRig; robustness and high performance matched with automation and intelligence.” The SmartRig ROC D65 is, according to its developers, an evolution in surface drilling that represents a milestone for the mining industry. “The SmartRig ROC D65 is the future when it comes to small-hole drilling in open-pit mining,” says Olav Kvist, Product Manager, Atlas Copco. “The ROC L8 and the SmartRig now come together to combine the best technologies that each one has to offer, creating a completely new drilling experience.” In practice, this means that in addition to the strength, power and reliability that made the ROC L8 notable, the SmartRig’s computerised rig control system (RCS) enables it to support the full drilling cycle, from hole navigation with automatic angle set-up, through to drilling, the adding and extracting of drill tubes and simultaneous time logging of performance. The rig integrates with the mine planning system, reducing the need for surveyors working on the bench. The log files support on-site communication, lessening the risk of communication errors between operators and the office. Safety improvements are also an important benefit. As this unit automatically adds and

Atlas Copco’s SmartRig ROC D65 brings full computerisation to DTH drilling thanks to its Rig Control System which automatically controls the drilling cycle

retracts drill tubes, operators are relieved of this tedious task and are free to prepare materials on the bench while the rig completes the hole by itself. Designed for the 110–203 mm hole range, the SmartRig ROC D65 uses Secoroc COP 44, COP 54 or COP 64 hammers and drills holes up to a maximum depth of 54 m (long feed version). A Caterpillar C15 engine developing 402 kW provides the power and an onboard Atlas Copco XRX10 compressor delivers a full working pressure of 30 bar. At Bauma Sandvik displayed the first model of its new generation of DTH, the DI550. It features a 324 kW diesel engine and a 24.4 m3 compressor air flow at 24 bar pressure, “making the machine a perfect match for the 5” DTH hammer,” the company says. This careful balance of power and hammer size results in a uniquely productive rig that keeps fuel consumption and operating costs to a minimum. Cost-effective machine performance is further enhanced by other advanced features, such as active diesel RPM control, optimised diesel RPM level during drilling and active control of compressor running temperature. Aside from high performance, the focus of the project was on simple and comfortable machine operation. Featuring a modern,

SURFACE DRILLING

A rig mounted ore analysis system, being developed by Atlas Copco and other partners, will be a great boon to all. Here it is seen under test on a Pit Viper in the arctic conditions of Aitik copper mine

accurate control system with simple icon displays and comprehensive service information, “the new DI550 enables seamless co-operation of man and machine,” Sandvik says. Operator comfort is further enhanced by the rig’s modern, over-pressurised and ROPS and FOPS-certified cab with advanced ergonomics, efficient air conditioning and excellent visibility. The large windshield comes with a strong safety bar that is easy to open for cleaning. The new, efficient dust collector with nonstop cleaning restricts the amount of dust emissions into the environment. It also improves filter lifetime, which reduces the need for maintenance. Other features that translate into easy maintenance and thus low downtime include the open layout of the engine compartment, easy cooler cleaning, modular compressor control system and simplified electric system. All daily maintenance points are located at ground level to simplify the process and improve safety of service personnel. A fast fuel filling option and large fuel tank further cut costly downtime. The new DTH line has benefited significantly from Sandvik’s solid experience in top-hammer drilling solutions. For example, the two product lines share many solutions, components and test procedures. These similarities create clear advantages for service and maintenance. The DI550 is designed to work at maximum performance when fitted with Sandvik’s RH550 hammers in sizes from 3” to 5”. These hammers come with bits ranging from 90 to 152 mm, with three different bit face designs. Sandvik and Cubex have established a global partnership for the distribution of the QXR DTH surface drills. This follows the dealer agreement for Sandvik to distribute Cubex underground mining products announced last November 2009. All global sales, customer

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service and aftermarket support for the QXR range will transfer to Sandvik. The companies are developing plans to ensure seamless transition and expect a continuation in the high levels of existing support and service for the fleet of QXR drills already operating globally. Manfred Schaffer, President of Surface Mining at Sandvik Mining and Construction says: “The QXR series is a perfect addition to our range of dedicated surface mining drills. The QXR range complements our existing offering and confirms our position as the productivity leader in mining. We are now able to present a broader offering to our customers to meet their surface mining drilling requirements. The integration of the QXR drills, combined with Sandvik’s global customer support, will represent huge benefits for our customers.” Kitch Wilson, President of Cubex says: “On

six continents, the QXR has already proved itself to be a productivity leader in down-thehole drilling. Now, with the global support of the Sandvik organisation, we are convinced these drills will be increasingly popular for a wide variety of drilling applications.” The QXR drills are fully self-contained, diesel-powered, high-pressure DTH drills. They are crawler-mounted and have tilting booms and feeds for maximum flexibility. They are used across a broad range of applications, including blasthole production drilling, pre-split drilling as well as pioneering and pit dewatering. A growing field is Reverse Circulation (RC) drilling for sampling and grade control. The QXR is best known for its robust mining design, matched with powerful compressors providing the capability of drilling with 34.5 bar air. A full range of engine and compressor configurations allow the machines to be optimised for 4", 5", 6" and 8" DTH hammers. Terex Mining, now Bucyrus International, last year introduced two additional options for its R20T hydraulic track drill—the carousel rod changer and single rod changer options. Designed as a field-serviceable, highproduction drill offering a 36 m2, the R20T further expands its capabilities with these options. Both ease maintenance requirements with features such as corrosion-resistance, selflubricating coatings on normal wear parts and pivot pins, which eliminate the need for lubrication. The carousel rod changer will hold five rods in the carousel and one 6.1 m in the feed for a total of six rods. The carousel can change either 3.7 m or 4.3 m steel. The single rod changer will hold a 3.7 m or 4.3 m rod in the magazine and 6.1 m starter steel in the The Sandvik DI550 will be market launched in the fourth quarter of 2010. A new feed and rotary head will be launched at the same time

SURFACE DRILLING feed. The unique carousel and single rod changer gate design aims to reduce maintenance requirements by eliminating parts and reducing rod change time. Addressing the time-consuming effort formerly required to change the size of the steel in a rod changer, the rod gripper design accommodates 38 mm, 45 mm and 51 mm drill steel. This design allows for minimal part change, and reduced changeover time and cost in the field. Other time- and money-saving features found on the carousel and single rod changer include: ■ Weight and number of parts is reduced due to a new hosetensioner design incorporated into the upper carousel mount; also neatly routes hoses and ensures proper alignment, helping increase hose life; the single rod changer has a similar tensioner that offers the same benefits ■ Improved rod-change time as a result of the powerful dual rod grippers ■ More efficient dust collection from a multiposition, pre-cleaner mount ■ Proper rod position is assured and vibrationprone sensor failures are eliminated on the

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Big rigs

Terex Mining's (now Bucyrus International) R20T hydraulic track drill

carousel rod changer due to the integrated carousel indexing and locking; also reduces component part complexity and count (the single rod changer uses a hydraulic cylinder to swing the rod in or out) ■ Components weigh less, providing for a full complement of steel in the carousel (six steels and one in the feed) and single rod changer to maximise hole depth.

The SKF rotary blasthole drill has also benefited from a carousel innovation. Because of differences in rock consistency - soft, intermediatesoft and hard, a mine customer in Brazil needed a drill that could quickly switch between tricone drilling for softer rock and DTH drilling for very hard rock. A completely new system was engineered and a job that would normally take up almost a half-shift of time, manpower and equipment now takes less than five minutes and is performed by the operator inside the cab, making this switchover extremely safe. This innovation is now offered as a hammer-tricone pipe rack for the SKF, SKS and SKL drills. P&H Mining Equipment says it continues to focus on increasing the reliability factor on its all-electric P&H 320XPC heavyweight and its diesel-hydraulic middleweight P&H 250XP production drills. That continuous improvement program, it says, is a primary reason for continuing good demand for those P&H drills – in particular, from highly remote and difficult mining operations including quartzite-capped iron ore in Canada's Quebec

SURFACE DRILLING The P&H 320XPC provides superior operability and ease of maintenance with an efficient deck design

province, taconite on the US Iron Range, iron ore in South Africa, Western US copper, and Western Canadian metallurgical coal operations. “We are seeing a positive perception on the part of operations and maintenance managers with regard to our drills,” notes P&H Product Management Director Curt Hanson. “We continually seek out feedback on any reliability issues, undertake systematic root cause and corrective efforts, and apply those upgrades and solutions to new and existing P&H drilling rigs. As a result, we are seeing repeat orders for our drills from what could be described as ‘extreme environment’ operations that want reliable equipment backed by reliable support.” Hanson cited examples of the upgrades that mines consider particularly valuable on P&H drills, including an advanced auto-drill system with vibration sensing, an upgraded extreme cold weather start-up, ‘soft-start’ controls that protect motors and controls from surge shock as well as advanced, user-friendly HVAC controls and systems. New vibrationtolerant LED interior and exterior lighting systems replace halogen lighting systems prone

to premature failure in harsh drilling situations. “There is no single advance that we can point to with regard to our P&H drills,” Hanson said. “Rather, it is a continuous improvement effort that we use to methodically take valuable feedback from the mines and combine that information with our design system to make these drilling rigs increasingly reliable, easy to maintain and productive.” Atlas Copco's Pit Viper 235 was one of the attractions at MINExpo 2008 and has been busy testing over the last 18 months. This 152-

250 mm blasthole drill has tested in quarry, gold and coal mining operations. Orders have also been received from Canada, Indonesia and Australia, and the deliveries and commissioning will take place during this summer. Dustin Penn, Product Line Manager, Blasthole Drills, says “the Pit Viper 235 has been designed with increased productivity in mind to limit the non-drilling times during a blasthole drilling cycle. For a machine of this class in a small package, the PV-235 has higher feed and retract speeds, greater pulldown loads, higher rotation speed and torque combinations, a 12 m single pass clean hole

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SURFACE DRILLING tower, faster jack extension times until they touch ground, higher tramming speeds, on demand efficient hydraulics and smart electronics to save on power, larger tanks to increase time between fuelling and watering, a new operator cabin with excellent visibility and

ergonomics in mind and the RCS platform to allow for technology upgrades.” An integrated air conditioning system and additional moulded insulation for noise abatement help ensure the operator is comfortable in all environments. An engine enclosure option reduces sound emissions and cold weather protection is provided with additional full length doors for easy service access. The PV-235 like the other machines in the Pit Viper Series was designed with maintenance in mind as well that includes easy filter access, open decking, ground level service centres, central valve stands, cable tensioning and larger sheaves for increased cable life, increased lighting and machine integrated tower access. The PV-235 has some features of special interest that are new and were not seen at MinExpo: ■ The new patented Atlas Copco twin cylinder break out-wrench. Breaking the pipe joint is done below the table and allows the deck fork to be used while clamping the upper rod and allowing for adjustment from 115203 mm outside diameter drill pipe allowing for wear

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■ The patented 0-30° angle package pivots at the tower base and remote pinning to the tower support with an integrated dust chute and hydraulic decking that allow for the deck to remain level at every angle position and maximises the cuttings area under the deck ■ The energy saving automatic hydraulic clutch option. The patent pending automatic

increasing the service interval and life on the air compressor. The clutch removes parasitic engine loads at start up as the compressor is not engaged, therefore decreasing engine load and increasing engine life.

Enhanced cabs Bucyrus last year introduced an enhanced, state-of-the-art operator’s cab for its 49HR line of rotary blasthole drills. The cab

Atlas Copco's patent pending automatic hydraulic clutch installed between air compressor and engine on a PV 235 blasthole drill hydraulic clutch between the engine and the air end has been introduced this year as a new option for the Pit Viper 235 series. The benefit of this clutch is that it will disengage the air compressor from the engine when the air end is switched off. In a traditional power package, the compressor consumes approximately 30% of its rated power at standby. Installation of this clutch eliminates fuel being used for this standby power consumption and allows for a low idle speed. While changing rods, levelling, or moving between the holes, the air compressor is disengaged allowing for power savings during those cycles as well as

enhancements were predicated upon the premise that drill operators work more efficiently when they are comfortable and alert. Both physical and cognitive ergonomic improvements were made, creating a first-class work environment that promotes productivity and safety! The new and improved operator’s cab for the 49HR series continues the company’s tradition of supplying EDGE Technology products to their valued customers. A major aspect of Bucyrus’s reconfiguration of the 49HR controls and console centred on improved ergonomics and comfort for drill operators. Subscribing to the theory that a drill

SURFACE DRILLING operator’s comfort level is directly correlated to the operator’s productivity, Bucyrus incorporated a six-way adjustable seat with a mechanical swing suspension into the cab design. In addition, in-seat controls were included, allowing drill operators to work in an ergonomically correct position. Between the seat and the front window, a footrest was added to aid in reducing operator fatigue and to help minimise lower back pain. All primary controls (e.g., drill operation controls) are included on the in-seat control panels, while secondary controls (e.g., air conditioning, lights, and boarding stairs) are on a secondary control panel, which is still within reach of the seated operator. Control positioning was designed with the operator in mind, grouping associated function controls within the same area on the panel, and establishing an ‘outside-in’ correlation between control sequencing and machine operation. In other words, to operate the machine, the sequence of controls used would begin on the outer portion of the panel and would progress inward in sequential order. Not only was physical comfort considered, so too was visual comfort. The operator’s on-board monitor was programmed for enhanced visibility in all conditions, including direct sunlight and night conditions. The incorporation of contrasting colours creates an aesthetically pleasing display, an aspect that has been tested and validated in the field. Likewise, operator screens were positioned to facilitate easy viewing without associated head and neck movement by drill operators. In conjunction with physical ergonomic improvements, Bucyrus addressed cognitive ergonomic hurdles with improved programming, making it more intuitive and robust. The enhanced programming includes ‘Active Logic Screens’ for all major drill functions. These screens allow drill operators to view and follow permitted actions to facilitate proper functioning of a given drill operation. In addition, the pre-set programs for ‘Program Drill Control’ (auto-drilling) have been increased from five programs to 20, covering more operating parameters than its predecessor. Both the Active Logic Screens and Program Drill Control enhancements incorporated universally recognised symbols which further contribute to their intuitive usability. Drill operators and drill maintenance personnel both benefit from selfdiagnostic program enhancements that not only alert operators that a fault has occurred, but also identify the source of the fault. This capability allows drill maintenance personnel to quickly repair the area in question in an effort to minimise drill downtime. It also allows maintenance personnel to mitigate safety risks associated with fault diagnostic activities. Ultimately, less drill downtime and mitigated safety risk equates to greater productivity and safety, a fact that Bucyrus is confident will positively impact the mine’s bottom line! The new operator’s cab is SAE-J 231 certified, making it Falling Object Protection Systems (F.O.P.S.) compliant. In addition, the new cab design allows for a better line of sight for drill operators, improving safety during propulsion and drilling operations. Bucyrus also offers an optional camera system to provide a 360° field of visibility for additional safety and production. Xstrata Coal needed a sound-suppressed drill for its Glendell mine in Australia to meet environmental standards when operating within close proximity to residential areas. It was required that the sound level be no more than 114 dBA, with an in-cab rating of 75 dBA or less. However, its Terex SKF drill was rated at a sound power level of 121 dBA at source with a standard cab rating of 78 dBA. Working with an external acoustic engineering firm, Terex Mining developed a sound-suppression package that encapsulated the power train (including gearboxes, engines, compressors and coolers), achieving a level of 111 dBA at source. A new modified cab achieved an in-cab rating of 65 dBA. To ensure these alterations did not affect the SKF’s

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SURFACE DRILLING ease of maintenance, all panels, mechanisms, etc., were either hinged or lightweight for easy removal and access. Terex also manufactured an oversized muffler that not only reduced noise but was also in keeping with environmental emission standards. Further noise-reduction adjustments were made to the dry dust suppression system, which uses fans spinning at 2,500 rpm that caused a spike in the noise readings. Xstrata quickly put the modified drill to work at Glendell from where Tony Israel, the mine’s Operations Manager, commented, “At Glendell, we have an absolute commitment to our environment and community. By working closely with us, Terex has delivered soundsuppression levels on our SKF drills that exceeded our expectations. This aligns with our goal of ‘beyond compliance.’” The SKF is a versatile performer that can be used for rotary or DTH drilling in a variety of rock formations and can drill 152-270 mm diameter holes. Other features of the SKF include: ■ Pulldown force of up to 27,216 kg and a hoist force of 21,364 kg allows the SKF to efficiently get in and out of holes fast ■ Patented Hydraulically Operated Break Out (HOBO) wrench is operated from the convenience of the cab so the operator can break joints simply and safely with the hands-free wrench ■ Four levelling jacks increase stability and allow the machine to fully use its power.

Rig management Flanders Electric feels that “while new technologies continue to optimise ‘downstream’ processes, the nature of the basic structures of the mining process in the field is sometimes forgotten. The fundamental processes of drilling, blasting, excavation, transport, and crush/convey are just those, fundamental, and the state of the art in these sectors is few, if any, steps removed from these processes as they existed 20 and 30 years ago. This is not to say that the technologies of the field equipment itself has not become more refined and sophisticated, but rather that the processes involved in the application of the equipment to the overall operation have not significantly changed. “In an effort to address these and other issues, Flanders Electric has developed several systems that apply ‘Smart Mining’ philosophies to these field processes. Blasthole drill automation is a first step in optimising field operations to enhance ‘downstream’ efficiencies and output factors.” Its ARDVARC™ (Advanced Rotary Drill Vector Automated Radio Control) is a drill

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control system that continuously monitors onboard systems and adjusts critical operational parameters to optimise drill efficiency. It is a scalable system with several levels of complexity available, offering varying degrees of benefit to the mine operator. At its most basic level, ARDVARC monitors and reports machine performance, allowing post-process analysis of machine data. Onboard faults can be configured to alert the drill operator with several levels of severity, providing advance notice of a potential impending failure. In this configuration, all OEM machine controls remain in place, and Flanders simply adds the monitor and report capabilities of a full ARDVARC system. At this level, the mine operator is provided with powerful and complex field data which can be applied to mine planning and fragmentation before the blasthole is loaded. This provides significant advantages over post-blast processing methods. The system produces a metre-by-metre profile of the ground as the hole is drilled. This data is invaluable in determining explosive loading, and at some operations, is used to alter the drill pattern on the fly, with an eye towards optimised fragmentation. Accurate positioning is another component, providing guidance to the operator for best hole location. ARDVARC is compatible with all HPGPS systems on the market today. If a property does not have an HPGPS solution in-place, Flanders Electric can

implement an economical, highly accurate GPS system without the need for complicated terrestrial location solutions. When a designed pattern is loaded into ARDVARC the machine operator is presented with a ‘bull’s-eye’ target at the console which allows for precision locating of holes per the blast plan, which contributes to optimal fragmentation. The next level of implementation is semiautomated drilling. In this configuration the operator propels the drill manually to each hole location and simply presses one button to initiate the drill cycle (One-Touch Drilling™) the drill cycle automatically sequences through monitored and controlled: ■ Extending jacks/levelling ■ Collaring ■ Drilling ■ Retracting the drill bit ■ Retracting jacks. Then the operator switches to propel mode, moves to the next hole and starts the process again. The operator can override ARDVARC at any time. The cycle can be manually manipulated for whatever reason and the operation then returned to ARDVARC to finish the sequence. The data collection system is a significant benefit, providing solid information – in real time – of the hole strata profile, which enables development of custom hole loading. This can significantly improve fragmentation. Material processing cost savings attributable to consistent fragmentation can be considerable. Additional benefits are accrued by proper use of machine health data. Real-time monitoring of on-board components provides opportunities to increase effectiveness of PM cycles. Predictive

The SKF can be used for rotary or DTH drilling

SURFACE DRILLING analysis of machine health data minimises missed opportunities (omission may result in critical component failure) for mechanical repairs before a failure. ARDVARC, at its highest level of implementation, is fully autonomous, with intelligent tramming added to the One Touch Drilling feature. In these deployments, it follows the blast plan independently of onboard operator intervention. Using the onboard positioning system an ARDVARC enabled drill can complete the entire blast pattern without input from human operators. It is typically monitored at a remote master control station located away from the actual drilling process. A single supervisor can operate five ARDVARC units concurrently. A shortrange remote control console is also provided which allows the operator to move away from the machine under hazardous safety conditions. By removing the human from the machine safety concerns are mitigated, primarily concerns arising from operation below high walls (rock fall danger), or on top, close to a potentially unstable edge (risk of drill rolling off into a pit or lower bench). Flanders Electric has had over 30 ARDVARC units in service for over four years. They have produced thousands of holes equating to hundreds of thousands of metres and have

never bent a drill steel. The system is adaptable to any machine, electric or diesel/hydraulic controlled. Other features of the system include: ■ Stuck pipe mitigation ■ Hole quality assurance ■ Hole collar quality management ■ Rotational stall protection ■ Proper auto-level each cycle ■ Failing hole protection ■ Dynamic drill parameters. To date, Flanders has replaced less that 15 components, with a total replacement cost of less than www.rockmore-intl.com $25,000. This excludes ARDVARC PCs and touch screens which have a life expectancy in a mine of about 24 months. One of the goals during development was to achieve 100% equality with topproducing human For more than 60 years, Rockmore operators. Flanders International has provided innovative drilling solutions, with manufacturing centers in Electric reports two hemispheres and a global distribution “ARDVARC routinely network. Rockmore high performance exceeds production of drilling tools exceed the toughest Rockmore International demands in mining, a site’s top human Wilsonville, Oregon USA construction, and driller by 20-30%. As Tel (503) 682-1001 water-well percussive [email protected] another benefit, drilling applications. Judenburg, Austria maintenance group Tel +43 3572-86300 performance can be [email protected] ® quantified by R o c k M o r e® reviewing collected International fault data. The Rock Drilling Tools effectiveness of a

Drill More

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The ARDVARC system in the cab of a blasthole drill

maintenance plan will be indicated by observance of decreased component faults over time. “By pro-actively protecting the equipment from misuse, maintenance requirements are minimised and machine availability goes up. In combination with more expedient hole production and greater consistency in hole variability, the maintenance factors contribute to overall efficiency that routinely outperforms strictly human operation. The repeatability of quality from hole to hole, in conjunction with individual hole profile data, ensures efficient blast effect predictability, which in turn promotes more consistent fragmentation.”

New tools Rockmore International’s ROK 875 is the latest addition to its ROK down-the-hole hammer product line. The 203 mm diameter class hammer has an integrated top sub that combines multiple internal parts into one component. It features SonicFlow technology to optimise airflow by simplifying the air path, which prevents energy from being lost through turbulence. With fewer obstructions, more energy is delivered to the piston while minimising backflow interference. Smooth radius ports in the airflow chambers further minimise energy loss. The high frequency, reciprocating piston is made from casehardened material. The hammer also features a heavy-duty wear sleeve and back reaming buttons. The ROK 875 accepts industry standard drill bits with 16 spline Ingersoll Rand QL8/QL80 shanks. Recommended bit sizes range from 215 to 254 mm. This new hammer is rated for use with large compressors and air packages, 24.1 bar at 39.7 m3/min. IM