Large diameter (LD) drilling either vertical piling or horizontal directional drilling is used in construction, utilities, telecoms & underground services. Historically LD vertical drilling systems have utilised pneumatic hammers up to 24” diameter & solid steel drilling bits which have advanced more recently to concentric drill bits, mechanical expansion segmental bits & overburden drilling systems used for hole expansion used for cased holes in construction piling. With ever increasing sizes of construction being undertaken from high rise buildings in Hong Kong, bridges & ports in Malaysia to wind turbines both onshore & offshore, the use of LD piling up to 1400mm & beyond is becoming more commonplace. LD canister drills or cluster hammers have been developed over the last decade in an attempt to improve the penetration rates when cutting LD piles through medium to hard rock formations. The concept of cluster drilling or canister drilling involves between four & nine smaller individual pneumatic hammers that are held together on a bolster or canister to provide the combined force both impact & rotational action to cut through varying rock (medium density formations such as gravel, clay & boulders & hard rock) formations. These systems have been found to be unreliable due to imbalance & stresses causing catastrophic failure & breakdown of individual hammers which are frequently experienced down the hole. Bulroc have 40 years experience in novel pneumatic hammer & drill bit design in both horizontal & vertical applications. The proposed LD hammer 33” & LD drill bit technology aims to be able to operate in both vertical & horizontal environments producing holes from 1250mm to 1400mm diameter from a single system in both medium & hard rock formations. Global piling equipment machines market was valued at US$4.31B in 2014 expanding to US$6.94B by 2022. (Grand View Research 2014 – Piling Machine Market Analysis).

The project was conceptually born out of the company's exploitation programme for the company's large diameter multi-functional drilling system. The major benefit for contractors in using the large diameter multi-functional drilling system was its ease of use in both vertical and horizontal drilling applications. Whilst the company developed its potential use in reverse circulation environments, the company quickly recognised that when reviewing this technology there were major failings when using existing concentric drilling systems and reverse circulation systems where new construction sites adjoined existing buildings. These failings resulted in the de-stabilisation of the geological sub-structure causing major structural damage and, in some instances, buildings that have become unsafe. Through working with senior structural engineers, drilling contractors and building site health and safety inspectors the problems with pneumatic drilling systems used in these environments have been identified with the industry considering the necessary courses of action that overcome such problems. However, with similar occurrences becoming more regular in 2008, both temporary and longer term changes are likely in the future. The existing short term solution has been to employ fluid flushing systems. However, Bulroc is aware of major problems in the use of this type of technology in terms of geological destabilisation. The second type of technology under consideration is a more costly combined air and fluid flushing system which Bulroc has developed around 10 years ago, but the company believe is not the answer. The technical team at Bulroc believe that all the problems with substructure de-stabilisation relate to the use of high volumes of flushing media (either compressed air or water) around the face of the drilling bit during operation which forces this media into the ground, causing both short term and longer term de-stabilisation. The company's proposed project would be the research, design and development of a revolutionary approach to flushing and cuttings removal. The proposal provides an introduction to the development providing aims and deliverables which assists in the measurement of overall progress, a reasoning for why the technology is required, project costs and durations, project location where the research, design and development would be undertaken, and why the grant for research and development would be needed in order for the project to go ahead. The technical aspects of the project (Section B: Technical Work Plan) are covered in the technical work programme which provides information on the research and development tasks to be undertaken and the anticipated technical risks which the company face during the project. The technical methodology is also detailed and provides an indication as to how the company plans to overcome areas of major technical uncertainty during the development project. The project phases break down the major project areas into specific work packages which help the company to identify castings for the project phases. A detailed project cost breakdown is provided, together with an indication as to how the company would fund its contribution to the project. The marketability of the proposed new drilling system is described in Section C. This section of the proposal provides background on the market including its size, geographical limitations, potential customers together with the company's exploitation plan, unique selling points and how Bulroc plans to protect the technology using different forms of intellectual property. The company has already submitted a provisional patent which is included in the Appendices of the project proposal. The final section of the proposal D: Business Development Plan, provides information on the background of the company, its previous support and how the business is moving forward with its existing products, and in what markets. This provides ample evidence that the company has exploited its previous major development projects, and provides full details on the position of the company and its plans to develop International markets in the future. The company is one of the world leaders in the design and development of pneumatic down the hole equipment and has re-established its strong position in terms of new products and technology from its once dominant position in the early 1980's when the equipment was in its infancy. The final section of the proposal also covers the impact the proposal would have on the company in consolidating the company's position within the industry, and positioning Bulroc for further growth in export markets as the civil engineering and construction markets recover into the next decade and beyond.