Top Reasons Maxi-Rig Operators Need the Largest All Terrain Directional Drill

For horizontal directional drill (HDD) operators who want to work efficiently, sending the right equipment to the jobsite is always important. But as both jobsites and equipment evolve, operators should take a moment to rethink what “right” means for certain jobsites. Maxi-rig horizontal directional drills have long been the go-to for large-scale projects. However, as operators expand into high-demand industries like fiber and other utilities, they often find themselves working in more compact, urban jobsites where maneuvering and transporting large equipment can be challenging. 

Meanwhile, Ditch Witch All Terrain horizontal directional drills are increasing in size, power and capabilities to meet a broader range of projects, including those traditionally reserved for maxi-rigs.

With the release of the Ditch Witch AT120, the world’s largest All Terrain directional drill to date, maxi-rig operators can move down a class size to meet jobsite constraints and increase jobsite productivity. While the AT120 directional drill is not a replacement for maxi-rig drills, it does complement those larger machines, helping operators save time and boosting jobsite productivity.

Mining the Gap in Fleet Class

The Ditch Witch AT120 gives operators the power to achieve efficient fiber, pipeline and utility installation through tough ground conditions. It delivers 15,500 ft•lbs of rotational torque, 120,000 pounds of thrust and pullback and 3,000 ft•lbs of inner rotational torque. The AT120 is not a replacement for some maxi-rigs, like the American Auger’s DD600, which has the power and capabilities for longer and larger installations. However, it is proving that it can still deliver the performance needed to take on large fiber, utility and oil and gas projects. For example, earlier this year, a Kentucky-based contractor experienced firsthand the enhanced productivity and power of the AT120. Tasked with installing 1,200-foot shots of 24-inch steel-cased pipeline, the project presented a variety of challenges, including working through diverse ground conditions and elevation changes ranging from 100 to 150 feet.

For jobsites that include tackling tough, varied terrains without compromising power, the AT120 drill can deliver powerful performance while being more adaptable on compact jobsites. Here are three (and a half) reasons why an operator should consider adding this drill to their fleet.

1. Improved Fluid Management

Large All Terrain drills significantly enhance fluid management and reduce associated risks on the jobsite. This improvement is because All Terrain directional drills do not require high volumes of drilling fluid to operate during a pilot bore. By pumping less fluid downhole, operators can reduce the risk of inadvertent returns, which often leads to costly cleanup efforts and downtime.

Because maxi-rig drills are equipped with mud motors, these machines send a higher volume of fluid downhole, resulting in increased fluid pressure. And when this pressure exceeds what a bore can handle, fluid can seep out of the bore, creating inadvertent returns. In contrast, an AT120  with dual-pipe technology uses its inner rod to turn the drill bit, reducing reliance on large amounts of drilling fluid.

Reducing the amount of fluid sent downhole not only lessens the risk of inadvertent returns, but also allows operators to utilize a smaller mixing system on the jobsite. This eliminates the need for a larger reclamation system, which occupies more jobsite space and requires additional transportation logistics. This streamlined approach enhances operational efficiency. It also simplifies jobsite management, making the AT120 a superior choice for fluid management on HDD jobsites.

2. Simplified Transportation and Setup

Minimizing the equipment used to reclaim, clean and reuse drilling fluid is another reason why an operator should consider adding the AT120 directional drill to their fleet. Large maxi-rig drills often require multiple semi-trailer trucks to transport them and their equipment to and from a jobsite. However, an AT120 directional drill and its accompanying equipment can be transported with fewer trucks and trailers.

Once the equipment is on the jobsite, setting it up is easier and more efficient, helping operators stay productive. For example, when an AT120 directional drill is delivered to a jobsite, an operator can quickly back it off its trailer using a remote control, drop its anchors and be ready to start a job. 

AT120 directional drills also have features like pipe loaders, which significantly speed up the process of loading pipe. In contrast, a maxi-rig drill requires excavators to load each pipe, a task that is both time-consuming and labor-intensive. Additionally, needing multiple excavators on-site increases the operator’s transportation burden and jobsite footprint.

3. Reduced Jobsite Footprint

Operators can work more efficiently when they have fewer and more compact pieces of equipment to manage on a jobsite. An AT120 directional drill requires less setup space than a maxi-rig. It can also easily maneuver in tight confines, like crowded urban environments. This allows operators to reduce jobsite footprint and minimize the impact of their work on the surroundings—like closing only one lane on a highway instead of multiple lanes.

Additionally, the space savings are even greater when considering the elimination of other equipment typically used with a maxi-rig drill, such as large pumps and mud motors. The footprint of AT120 drills becomes significantly smaller, making it easier to manage. Having less equipment and drilling fluid to handle can also lead to more productive and profitable jobsites.

4. Easier Utility Locating

Utility locating systems may be separate from the drill, but they are an essential component of every underground construction project. With the AT120 directional drill, the locating process is greatly simplified. Wireline locating systems are commonly used on maxi-rig drill jobsites. These locating systems provide the accuracy operators need to guide their large drills underground. But they’re also time and labor-intensive, requiring a team of multiple people to lay out a grid of heavy copper lines and then meticulously locate across that grid.

However, HDD jobsites that warrant an AT120  directional drill can utilize walkover locating. This method involves just one person using an HDD guidance tool, like the Subsite^® Marksman^™ Plus system, to monitor the bore path as they walk along it. This not only helps operators reduce labor costs, but also enhances efficiency and accuracy on the jobsite.

Right-Sizing Fleets for Today’s Jobsite Needs

The HDD industry continues to evolve, and the introduction of the AT120 directional drill marks a pivotal shift for maxi-rig operators looking to stay agile without compromising on performance. These machines bridge the gap between traditional maxi-rigs and the demands of modern, urban jobsites—giving operators a new option to consider for their fleets. By offering improved fluid management, simplified transportation, easier setup times, reduced jobsite footprint and streamlined utility locating, the AT120 helps operators tackle complex projects with the same efficiency and effectiveness as its larger counterparts.