WELCOME TO RC DRILLING (https://www.rcdrilling.

com)

1. What is RC Drilling?
Basics of Reverse Circulation Drilling
RC drilling uses rods with inner and outer tubes, the drill cuttings are returned to surface inside the
rods.
The drilling mechanism is a pneumatic reciprocating piston known as a hammer driving a tungsten-
steel drill bit.
RC drilling utilizes much larger rigs and machinery and depths of up to 500 metres are routinely
achieved.
RC drilling ideally produces dry rock chips, as large air compressors dry the rock out ahead of the
advancing drill bit.

RC drilling is slower and costlier but achieves better penetration than RAB or air core drilling;
it is cheaper than diamond coring and is thus preferred for most mineral exploration work.

Reverse circulation is achieved by blowing air down the annulus of the rod, the differential pressure
creating air lift of the water and cuttings up the inner tube which is inside each rod.
It reaches the deflector box at the top of the drill string then moves through a sample hose which is
attached to the top of the cyclone.

The drill cuttings travel around the inside of the cyclone until they fall through an opening at the
bottom and are collected in a sample bag. For any drill hole there will be a large number of sample
bags, each one marked to record the location and drilling depth that the sample was obtained.

The collected series of sample bag cuttings are later taken for analysis to determine the mineral
composition of the drill hole. The analysis results of each individual bag represents the mineral
composition at a particular sample point in the drill hole. Geologists can then survey the drilled ground
analysis and make decisions about the value of the overall mineral deposit.

RC Drilling Rods
RC drill rods have an outer & inner tube with a sealing system (usually “O” Rings or custom made
urethane seals) to keep the drill string pressurised. As rods are subjected to high wear in the drilling
process only the highest quality hardened alloy steel is used for the tool joints. These higher quality RC
drill rods are manufactured by specialists like Harlsan in Australia.

The most commonly used sizes for RC Hammer are 4” and 4 ½”inches. RC Hammers have round metal
‘buttons’ that protrude from the bit, which are required to drill through rock and shale. As the buttons
wear down, drilling becomes slower and the rod string can potentially become bogged in the hole.

This is a problem as trying to recover the rods may take hours and in some cases weeks. The rods and
drill bits themselves are very expensive, often resulting in great cost to drilling companies when
equipment is lost down the hole.
Most companies will regularly ‘sharpen’ the buttons on their drill bits in order to prevent this, and to
speed up progress. Usually, when something is lost (breaks off) in the hole, it is not the drill string, but
rather from the bit, hammer, or stabiliser to the bottom of the drill string (bit).

This is usually caused by a blunt bit getting stuck in fresh rock, over-stressed metal, or a fresh drill bit
getting stuck in a part of the hole that is too small, due to having used a bit that has worn to smaller
than the desired hole diameter.

Although RC drilling is air-powered, water is also used, to reduce dust, keep the drill bit cool, and assist
in pushing cutting back upwards, but also when collaring a new hole.

A mud called liqui-pol is mixed with water and pumped into the rod string, down the hole. This helps
to bring up the sample to the surface by making the sand stick together. Occasionally, ‘super-foam’
(AKA ‘quik-foam’) is also used, to bring all the very fine cuttings to the surface, and to clean the hole.

When the drill reaches hard rock, a collar is put down the hole around the rods which is normally PVC
piping. Occasionally the collar may be made from metal casing. Collaring a hole is needed to stop the
walls from caving in and bogging the rod string at the top of the hole.

Collars may be up to 60 metres deep, depending on the ground, although if drilling through hard rock
a collar may not be necessary. RC drilling equipment has come long way from this method of drilling
angle holes in the mid 1960s.

2. RC DRILLING RIGS
Type of rig required for RC & multipurpose drilling
There are numerous options to be considered by a drilling contractor before purchasing an RC Drilling
rig which would include but not be limited to,

 Track v truck mounted rig

 Multipurpose rigs that do both RC and diamond drilling.
 Air capacity for depth and size of holes needed
 Health and safety features

Track versus Truck mounted rig

Track based, deep hole RC exploration rigs are a more stable platform therefore giving better hole
alignment and less hole deviation. Track based rigs are appealing to clients as they can reach depths of
up to 800m on rugged terrain and also reduce the impact on the environment because they are
manoeuvrable with a smaller footprint.

A truck mounted rig has the primary advantage in that it can be driven long distances between drilling
sites were as a track mounted rig needs transporting on a low loader. Modern eight wheel drive trucks
can also access increasingly rugged terrain.
Multi-purpose Rigs
A multi- purpose rig can drill both RC and diamond and eliminates the need for having two rigs in a
case where both RC and diamond drilling are required. There is cost and time savings as the machine
can combine RC and diamond drilling within the same hole.

Air Capacity
One of the key factors when looking at a rig for drilling RC or air core is the air capacity as this will
determine how deep holes can be drilled. With advances in air compressor designs new RC rigs have
on board air capacity up to 100cfm at 450psi to provide both high pressure and high volume air.

This enables 4’ – 4 ½’’ RC Hammer holes to be drilled to depths up to 400m without using boosted
auxiliary air saving time and money in machinery and setting up. Another advantage of large air
capacity is that improved penetration rates that can keep holes dry up to several hundred metres
improving sample quality and handling of sample bags.

Health and Safety Features

One of the critical areas in RC drilling is the breaking out and handling of rods. New hydraulic drill rod
break out systems allows RC drill rod joints to be both mechanically tightened and untightened
without any physical contact from the operators, when combined with automated rod handling
systems this eliminates one of drillings highest safety risk activities. Modern RC rigs can also be
equipped with remote drillers console so that a driller can operate the rig safely at a distance of up to
15m.

Other safety features to consider include noise and dust suppression as well as hand rails, access
ladders, lighting and fire extinguishers’ that meet relevant industry standards.

Dump Mast
A key feature of RC rigs is the dump mast which allows holes to be drilled at angles from 90-45
degrees. This is critical as geologists like to intersect the ore body at an angle of 90 degrees.

3. Setting up for RC Drilling

When setting up or buying a rig to commence RC drilling there are a lot of factors to consider. Initial
costs are high so you need to get it right the first time. Talking to peers in the industry plus rig and
consumable manufacturers is a great way to get firsthand experience so that costly mistakes can be
avoided.

Harley Hollier from Harlsan Industries, a leading consumable supplier highlights the importance of
paying careful attention to initial equipment purchases.

Choices like the type, configuration and setup of a rig has downstream affects on production rates,
downtime, profitability and operator safety.

There are two types of RC Drilling

RC with hammer, used in medium and hard rock and can reach depths up to 800m. Rods are usually
4’’ and 4 ½’’ diameter.
Aircore, to drill softer oxide and clay ground to depths of 100m using Air Core & Vacuum Bits. Rods
are normally 3’’ to 3 ½’’. Some companies will specialise in Aircore Drilling.

Track versus Truck Mounted

Rig Carrier Type – Truck v Track Mounted

Track based, deep hole RC exploration rigs are a more stable platform therefore giving better hole
alignment and less hole deviation. Track based rigs are appealing to clients as they can reach depths of
up to 800m and also reduce the impact on the environment because they are more manoeuvrable
with a smaller footprint.

A truck mounted rig has the primary advantage in that it can be driven long distances between drilling
sites whereas a track mounted rig needs transporting on a low loader. Modern eight wheel drive
trucks can also access increasingly rugged terrain.

Ancillary equipment like support trucks & vehicles

As well as the drilling rig, reverse circulation setups usually consist of a support vehicle, an auxiliary
vehicle & 4wd light vehicles.

The support vehicle is normally a truck in the range from a 3 tonne 4WD truck (which can hold 1,000
litres of fuel & 750 litres of water) up to a full sized 8 x 8 which can carry 6,000 litres of fuel, 2,500
litres of water, 300m of 4 ½’’ spare rods and other supplies needed for maintenance.

The auxiliary vehicle is normally required to transport auxiliary compressor & booster units when
drilling deeper holes requires boosted air. If drilling is to continue at night lighting plants will also be
needed.

Compressors
RC rigs have their own compressor and sometimes a booster to generate air pressure. Compressors on
an RC rig normally have an output of around 1000 cfm at 500 psi (500 L·s-1 at 3.4 MPa). The depth of
hole that can be drilled will be determined by the amount of air.

If extra air pressure is needed to drill deeper holes the engines are mounted on the auxiliary vehicle. A
fairly standard set up would be an RC rig with on-board air of 1350cfm/500psi which would achieve
drilling depths of 300-400metres. If required an Auxiliary Booster Air Truck can be added upping the
capabilities to 2700cfm/1000psi and increasing hole depth to 800metres.

Drillstring

Once a drilling company has purchased a new rig they will need to fit it with a drill string.
The drill string covers the consumables and includes
- Hydraulic Blow down,
 - Inlet Swivel,
- Adapter &
- Saver Subs,
- RC Drill Rods,
- DTH hammer or Air Core Bits

There are a number of different variations to how the drill string can be set up, so taking the time
talking to a supplier who knows the industry is critical.

A good starting point would be to vist Harlsan Industries at www.harlsan.com.au. They regularly help
drillers can make the right decisions based on their years of experience designing, manufacturing &
supplying RC drilling consumables.

Sampling
The sole purpose of RC drilling is to obtain accurate samples of the ground being drilled. The sample
travels up the inner tube and is usually diverted 90 degrees at the wear bend or deflector box to slow
down the speed of the sample.

A knock on nut connects the sample hose to the deflector box which usually has a ceramic or metal
wear plate that is easily replaced in the field. The sample then travels through the sample hose to the
cyclone which further slows down the sample and also separates the sample from the air which goes
out through a dust collector.

A good cyclone is critical to obtain accurate samples. At the bottom of the cyclone is the dump box. As
one sample is in the dump box another is collecting in the cyclone so there is no need to stop drilling
during the sampling process. From the dump box the sample is dropped into the splitter which
reduces the size in a range from 6.25% to 12.5%.

A list of equipment for a standard RC drilling rig

 Top Hydraulic Drive
 Compressor (preferably around 750 HP, 1250CFM/350psi)
 200 meter capacity automated rod handler
 Hands free automated breakout system
 Down hole survey 400mtr x 6mm non rotating wire line
 Heavy duty 2 meter mast dump feed system with 19000kg variable pull back
 12,300kg variable pull down
 Cyclone sample & SP1 horizontal
 Support truck

These specifications are suitable for any RC drilling requirements, including grade control,
mineral exploration, resource definition and water bores etc.

For RC Sampling the cyclone and splitter can be mounted on the drilling rig or on a separate
truck or trailer. The advantage of a separate trailer mounted cyclone & splitter with dust
suppression is that it provides accurate sampling in a hazard free environment away from the
rig.

4. What’s Important to an RC Drilling Program

Quality of the sample

While there are a numerous factors to be considered when looking at the type of drilling method for
an exploration program, ultimately it’s the quality of the samples that is the most important.

Geologists must have confidence in the accuracy of the sample and way that up against the time and
cost involved. When that is done it’s easy to see why RC Drilling with its recent technical advances has
become the preferred method for exploration drilling.

While diamond drilling will continue to be used were helicopter is the only means of getting a light
weight rig to the site, RC drilling continues to expand into geographic areas and to depths that were
traditionally done by coring.

Time factor
In the exploration game time is money. Mining companies want their drilling programs done quickly
and accurately. RC Drilling can be three times as productive as core drilling and a 250-300m hole can
be drilled in a single 12hr shift depending on rock formations, the overall drilling conditions and the
skill of the driller.

Aircore drilling in unconsolidated ground is a fast way to get accurate samples and is becoming more
preferred than RAB as the means for initial exploration drilling.

With the air capacity of modern RC rigs drilling with hammer can be done below the water table to
depths of 500m and still keep the sample dry, which is a key factor in handling and analysing the
sample.

Show me the money

Geological exploration is a risky business. With investors looking for a return and mining companies
needing to keep the market updated with their drilling results there is always pressure to get drilling
programs completed and results analysed.

RC drilling enables mining companies to get fast and accurate results enabling junior mining
companies to raise further capital to continue drilling. In a lot of cases the initial RC holes will be used
as a precollar for diamond drilling to greater depths.

In pit grade control

RC drilling (In pit grade control) is used in open cut mines to define ore grades and also provide
knowledge for mine planning and blasting. This information is critical to reduce waste rock (dilution) in
concentrator feed as dilution can vary from 5-40%. RC grade control is the most cost effective and
accurate way to define boundaries between waste rock and ore bodies

Multifunctional Survey Tools

Although drilling techniques and equipment has made tremendous advances it is still not possible to
drill an exact straight hole. The exact path of the drill hole is essential for economical evaluation of
mineralized rock formation, geological mapping and geophysical down hole surveys.

Multifunctional Survey Tools are electronic instruments that measures the inclination and direction of
a drill hole, along with magnetic and gravity field components. They are multifunctional tools with
single and multi shot capabilities.

Spiral Stabiliser Subs

Spiral stabiliser subs improve the accuracy of deep RC holes & are a valuable addition to any RC drill
string.

“While drilling 360m deep RC precollars we experienced problems with deviation of more than 5
degrees at the end of the hole. The Harlsan spiral stabilizer sub dramatically improved accuracy,
enabling us to keep the holes within 1-2 degrees”
(Kennedy Drilling Australia).

The exact path of the drill hole is essential for economical evaluation of mineralized rock formation.

5. RC Drilling - The Benefits

Advantages of Reverse Circulation Drilling

Compared to core drilling, RC drilling with inherently faster penetration rates provides several
benefits:

o Direct drilling cost reductions in the range of 25% to 40%.

o Faster completion of drill programs with quicker delivery of results.
o Reduced man-hours at the drill with decreased exposure to potential accidents.
o Reduced contractor activity in the mine reduces mine support burden.
o Indirect cost reductions gained from a simplified sampling process.
o Requires less water than diamond drilling.

RC samples are collected at the drill and sent directly to the assay lab.
Unlike diamond drill core, which is generally logged, photographed, split for sample, assayed and
warehoused, RC sampling requires much less handling resulting in faster assay turnaround with
accompanying cost reductions. Larger volume RC samples often give more representative gold
samples than split half core samples.

There are however some cons to RC drilling

o Less geological information from sample.
o Holes can deviate (Spiral Stabiliser Subs keep holes straighter)
 o Diamond can usually drill to greater depth although depths up to 800m have been achieved
with RC Drilling.

Comparative cost of Exploration Program and Budget for a standard project in 2011
Follow-up exploration will be staged and conducted over a 12 to 24 month period and should include
but not be limited to:

o A total of 5,000 soil and rock samples collected across the property;
o Prospecting and mapping over the newly granted tenements;
o A 10 hole combined RC and diamond drill program in 2011 to test the continuity and extent of
gold mineralization intersected during 2008 at the Wealth of Nations Prospect;
o To test a number and variety of quality gold in soil anomalies specific target areas;
o A number of RC or diamond drill holes are required to test the airborne and subsequent
ground EM targets identified in association with surface gold at the target areas.

The estimated cost to conduct the surface sampling program is $AUD500,000. Proposed At an all up
cost of approximately $AUD 120 per metre for 12,500 metre of RC drilling and $200 per metre for
2,250 metres of diamond drilling, it is anticipated that the drilling program will cost up to
approximately $AUD 2,000,000 to complete. The program will be staged and conducted over a 12 to
24 month period.

6. RC Drilling Comparisons

RC Drilling compared to other drilling methods

Reverse Circulation (or RC) drilling is one of the most frequently used methods of drilling used across
the world as it is more cost effective and efficient then other methods of drilling. When compared to
RAB (Rotary Air Blast) and diamond drilling, RC drilling seems to be somewhere in the middle when it
comes to cost, time, quality of samples, technique and depth.

FEATURE RAB DRILLING RC DRILLING DIAMOND DRILLING

COST Low Reasonable High
TIME Fast Efficient Slow
SAMPLE QUALITY Low Reliable High
DEPTH 0m – approx 125m 0m – approx 500m 0m – approx 1800m
TECHNIQUE Air forces rig Air forces rig Air forces rig through
through the ground through the ground the ground and brings
and brings rock and brings rock rock chip samples to
chip samples to chip samples to surface inside the Inner
surface outside of surface inside the Tube
Inner Tube Inner Tube
Cost

Because it is less complex and time consuming reverse circulation drilling is usually 25 – 40% cheaper
than diamond drilling. RC is more expensive then RAB which is used in initial exploration in shallow
softer rock formation to a depth of p 100m.

Diamond drilling consumables are also more expensive as they are custom made to suit the rig. There
are also significant cost and time reductions in the overall RC sampling process. RC can be used to drill
up to 500m in depth as a precollar to diamond drilling which is a cost and time effective method that
is often used.

Time

RC drilling takes less time than diamond drilling, but more time then RAB drilling because the
technique is more complex. Aircore is faster than RC with a Hammer as aircore is only used to drill
unconsolidated ground.

Diamond drilling is the most time consuming as drilling is done slowly to preserve the life of the parts
and also because of the rock hardness at depths between 1200 – 1800m. RAB drilling takes less time
as it is the simplest method of drilling.

Quality of Samples

The quality of the samples also depends on the type of drilling used. RC drilling gives accurate
uncontaminated results because the sample passes up the inner tube of the rod string to the cyclone
which collects up to 99% of the sample.

The cyclone separates the sample from the dust and air before it passes into the splitter which can
give the geologist varying sample sizes depending on their requirements. RAB drilling creates chips of
uncertain results as the sample is flushed up the outside of the hole and can be contaminated.

Although Diamond drilling creates a sample of very reliable results and also gives more geological data
it is more complex and time consuming in both the drilling and the analysis process. Another
advantage of RC Drilling is that it can be used in both exploration and for in pit grade control.

TECHNIQUE

Reverse circulation
Drilling creates chips (like RAB drilling) using either air core or RC hammer and brings them to the
surface inside an inner tube to prevent contamination. This provides a method of drilling that is fast
and effective.

With the recent technical advantages in RC drilling and the use of auxiliary compressors which boost
air, depths up to 500m can be obtained with a hammer and 300m with air core. Boosted air also keeps
the sample dry which makes it easier to split and improves the general handing of the samples.
RAB drilling
Uses a pneumatic hammer or rotary blade (drag bit) compressed air is forced down the centre of the
rod and the sample passes up the outside of the hole. RAB is normally used in initial exploration at
relatively shallow depths and is not as accurate as reverse circulation.

Diamond Drilling
Uses a hollow, cylindrical diamond encrusted drill bit which rotates at high speed, cutting through the
fresh rock and extracting a solid sample that travels up through the drill pipe. Water is also used for
lubrication, cooling, and removal of drill cuttings from the hole. Although diamond drilling provides a
solid core that gives more geological information it is more complex and thus relatively expensive and
time consuming.

Depth

The depth achieved by the Drilling rigs depends on a variety of factors including the consumables
being used, skill of the driller, air pressure and the type of ground being drilled. In exploration RAB
drilling can reach depths of approx 100m, RC drilling can reach depths up to 500m and diamond
drilling depths up to 1,800m.

Stabiliser Subs can be used in RC drilling to significantly improve the accuracy and efficiency of drilling
programs.

7. Comparative Costs of Drilling