In 2004, Chris started as a driller’s assistant with Drillcorp at Sunrise Dam, drilling initial diamond coring holes at Tropicana mine when it was still an exploration site, before moving onto deep directional drilling programs at Leonora and Forrestania. In 2006, Chris joined Boart Longyear (BLY) initially as a driller, before moving into a supervisory role at BHP Billiton’s Leinster and Mt Keith operations. This was when Chris developed a thorough appreciation of industry safety, and he’s grateful for the front row seat during a notable period of change in safety systems and workplace cultural maturity. In 2014, the Great Financial Crisis adversely impacted Australia’s mining and exploration with widespread reduction across all surface drilling. Chris was redirected to BLY’s Waterwell division across multiple Pilbara sites. Chris eventually returned to the Goldfields to assume a regional supervisor role before being rewarded with his current role as operations manager for BLY’s underground division, APAC.

Chris Hopkins: My father worked within Chevron’s lubrications business, collecting many small-scale models of heavy mining equipment. As a kid, I was fascinated by his ‘toys’ – sparking my interest and a subsequent stream of questions to my patient, receptive Dad who has since retired. I greatly admire my Dad for his genuine want to be of value to his community and local church. At age 24, I became a father for the first time while working in the liquor industry and wanted to veer to an industry where hard work, commitment and dedication were appreciated. I was also itching for adventure and a change in scenery, having been inside a lively wine store for too long. The prospect of working in the great outdoors at remote locations, being physical, and solving mechanical issues really appealed, so I made the switch.

CH: My professional role models and mentors include the esteemed and respected likes of Dale Barron, Des Forde, Gregor Stephenson, the late John Emerson, and Murray Hillier. Their collective drilling knowledge, willingness to engage and educate, while offering support has had the most profound effect on my career.

CH: I can’t recall a specific moment or project, as I’ve enjoyed many adventures during my career. Drilling challenges me on so many levels – from working and living away in remote locations and interesting environments, to geological undertakings through difficult formations, and the eventual satisfaction of completing a deep directional drilling program. In true A-type style, I beam with unwavering pride when my rig, fleet and team present well and drill effectively.

CH: 1. Good work habits and a positive mental attitude: the underground space is a very physical and challenging workplace, but it’s also a great place to work – I love it! Every task has an exacting set of measures which must be followed, as short cuts are not tolerated. Determination and attention to detail is necessary given the restricted work areas, equipment limitations and specific underground drilling requirements that can vary from +90 to -90 degrees. Excellent communication is paramount as daily interaction with mining teams is necessary to deliver quality samples within specific time frames. It is quite common for a mining team to immediately assume an area once drilling is complete.

2. Safety culture maturity: we must respect and understand our working environment, and maturity toward safety is a prerequisite to the underground mining sphere, given the inherent risk in what we do. I cannot and will not tolerate immaturity or lack of focus as either will result in someone being hurt and equipment being damaged.

3. People: are the most important and defining facet to success – in any industry. People who genuinely care and take pride in their work and accomplishments are who you want on your team. I’ve been fortunate to have worked with talented and capable people, and I’m most proud of my current team – they are enthusiastic, professional, highly motivated and experienced. We’ve developed an amazing and supportive working culture as a result.

CH: My somewhat cheeky response is whatever drilling type I’m currently focused on and involved in. Seriously, every discipline – underground or surface drilling has its own challenges including ground conditions, technical drilling requirements to achieve targets, underground grade control programs requiring multiple rig locations and set-ups per shift, to large diameter holes requiring large tooling to complete. The challenge of individual hole completion is what deems the drilling industry such an exciting business to work in. Up-hole drilling is a constant challenge, as underground geology departments strive to keep costs down. Sometimes the only way or location to achieve target is to drill ‘up’. Boart Longyear’s Roller Latch system allows crews to successfully and safely do so while following best drilling practices.

CH: Underground mining and drilling teams work closely, attending the same pre-start meetings and engaging more frequently than would occur at surface. When underground, everyone is under the supervision of the shift boss and underground mine manager, with increased engagement with the mining safety team. My drilling team has forged greater cohesion between the two groups, implementing exemplary practice and innovation that has been adopted by all, and I couldn’t be prouder.

CH: There are two reasons – risk and cost. Drilling is dangerous especially when poorly managed, so it makes sense to hire a professional contractor to complete the work. Contractors must be accountable and continually improve to secure future work. A lot of effort goes into delivering safe, seemingly hassle-free (for the client) drilling. Then there is cost. Most mining companies are incapable of cost-effective and productive in-house drilling. Contractors remain focused on achieving safe and productive outcomes for their ongoing financial survival and reputation.

CH: Delays associated with mine blasting and other mining activities significantly reduce the amount of time drilling crews must complete work, while eliciting an added expense to the client. BLY’s Drill Control Interface (DCi) system enables continuous drilling, even while the rig is unattended. Semi-autonomous capability within the underground drilling space is subject to an anticipated transformation, and it’s an exciting time. Many mines have, and continue to install underground Wi-Fi communication systems for enhanced communication between the drill crew and surface-based support crew.

CH: The underground space is in need of innovation, and Boart Longyear’s dynamic approach has meant that I’ve been involved in the development and release of some of the industry’s leading improvements including Roller Latch, diamond coring bits – designed and tested in the field by our drillers, and safety improvements to both drilling equipment and in the field training systems. Our fleet features machines that enhance the driller interface with improved safety and increased performance thanks to BLY’s ability to design and manufacture reliable rigs and drilling equipment, backed by adept and supportive maintenance teams, and an extensive global supply chain. I’m particularly excited about current innovations and advancements we expect to release within the next year. I can’t elaborate just yet, so watch this space.

CH: Most Australian underground drilling is N-size as it yields clients respectable sized core samples for the cost. For drilling contractors, N-size improves productivity with wireline systems, reduces manual handling when compared to conventional systems, and improves hole completion in poor formations. Boart Longyear’s Roller Latch system also provides much safer operations when drilling up holes, veering away from conventional processes.

CH: The potential to intercept an underground water source when drilling underground is both great, and undesirable. Thorough planning, detailed risk assessment and experience round out the high-pressure prevention trifecta, coupled with having the necessary tooling at the ready – should it be required.

CH: Drilling fluids are critical to hole completion in broken, unstable or pressurized formations – supporting all aspects of hole conditioning from reducing torque, assisting in the removal of cuttings, increasing hydrostatic pressure, stopping hydro sensitive formations from reacting, and some products hold together loose formations. Cost is critical and all staff – not just drilling crews must be educated as to correct usage to ensure zero to minimal wastage as this can greatly affect cost per meter. Reliable terminal equipment is key to ensure the most time down the hole. I’ve encountered many holes where formation stability is greatly reduced due to tripping of rods or introducing unnecessary pressures onto the formation, leading to extensive hole cleaning which then increases the likelihood of an unsuccessful hole completion.

CH: Boart Longyear makes use of wedging in both surface and underground operations. Wedging needn’t be a safety concern if effective planning and good communication are upheld. Importantly, we work closely with our clients to ensure this is the best option for them, as the cost to drill a new hole within the underground space can be cheaper than attempting directional drilling.

CH: Cementing works best when it is kept simple, checking everything twice. Like the carpentry adage, ‘measure twice; cut once.’ Training is key – as it is with all aspects of drilling. Be mindful of setting and correctly calculating grout volume. Other points to note: is the cement type correct or best suited to the formation? Is the product within its best before date, and has it been stored correctly? Are the slurry volume calculations correct? Is the potential for contamination being limited while mixing and displacing slurry? Be sure to extract a slurry sample to reference. Importantly, if you’re using an additive, be sure to follow the manufacturer guidelines as more is not always better. Lastly, don’t feel pressured when attempting as this is when most mistakes do occur. In Australia, we use VAN RUTH® cementing plugs as they’re a proven product that work well.

CH: Lack of preparation. A driller’s day starts with the all-important pre-start meeting, where supervisors outline and ensure that their teams understand what is expected to occur during that shift. Appropriate and reliable equipment is made available for the crew to safely complete every task and activity. Rushing to complete a job, particularly due to failure to plan, or lack of preparation is a recipe for disaster – namely injury.

CH: I’ve been fortunate to have been involved in many deep directional drilling programs throughout Western Australia, however, it’s important to note that this drilling method varies from production-based drilling within the underground space. The focus is on hole completion and hitting the desired target. It’s complex, extremely technical, and requires intensive supervision, as every decision affects how the hole is drilled from start to finish. I enjoy drilling at depth – the planning, preparation, and necessary attention to detail (correct choice and use of equipment, barrel configurations and monitoring the hole’s deviation) to achieve target. It’s a proud moment to be part of a team that successfully reaches end of hole, delivering a sample of an ore body to a client from over 2000-meters depth.

CH: Directional drilling using down hole motors is an effective method to hit multiple targets from a ‘parent’ hole. The method is best applied to deeper targets and areas where the cost to drill through waste rock exceeds the cost to complete the directional requirements to reach the targeted zone.

CH: The survey industry and its products are rapidly advancing in capability and reliability, with fantastic products available. Most importantly, the system must meet client requirements and be easy to operate, with flexibility for drilling teams to utilize tools to maintain effectiveness. I’m a firm advocate of the Azimuth Aligner® as it reduces rig set up time and relieves pressure on mine survey teams.

CH: Mining is critical to Australia’s economy, and every operation has been closely monitored to eliminate or minimize risk. Australia truly is the ‘lucky country’ for a few reasons – our geographic isolation and relatively small population combined with our swift acting government’s measures (international and state border lockdowns and mandatory 14-day self-isolation), has so far protected us as a nation. Over 25 million people live in Australia, yet our death rate from the pandemic is deemed low – just over 100 people. We must never be complacent and we’re mindful of the much talked about second and third phases, hence Australia’s strict border controls.

CH: Exciting technologies are being harnessed and adapted within diamond drilling. Many contractors are relentless in their pursuit to remove manual handling for a twofold result – eliminate and minimize injuries, while encouraging the broader community to consider the profession. Drilling cannot occur without people and the industry benefits when dedicated, focused and diligent people continually strive to improve perception and conditions. People are the future of drilling, so we must ensure that our industry evolves with safety, education, innovative systems and solutions at its forefront, as evidenced by key groups such as Australian Drilling Industry Association (ADIA) – endeavoring to improve standards and protocol for collective success – now and in the future. I’m currently involved at a research and development level, applying expert advice and feedback to hone various soon-to-be-released Boart Longyear equipment and tools that will greatly improve safety and productivity, while questioning how we approach drilling. It’s an incredibly exciting time to be in the industry and I personally cannot wait to see it come to fruition. Watch this space!

On one particular project, Boart Longyear mobilized underground coring rigs to a client’s mine in the US where the mine was faced with a big water problem that was making the underground exploration coring impossible to complete. The mine had two shafts located at different levels, one above the other. The deeper shaft had pumps installed and was ready to pump water to the surface. However, the upper shaft had flooded with water – where there were no pumps.

Typical underground coring setup.

Rather than attempt to install additional pumps in the flooded upper shaft to remove the water, Boart Longyear moved their underground coring rigs down to the lower shaft and drilled a fan-shaped series of up-holes to the flooded shaft above. The idea worked, effectively using gravity to drain the water from the upper shaft to the lower shaft where the pumps were then able to move the excess water to the surface. The mine was able to continue operations in the upper shaft and Boart Longyear was able to start the diamond coring exploration drilling.

On another project, the mine was thought to be dry. After the underground coring began, the Boart Longyear crew ended up finding water – a lot of it, quite unexpectedly. The crew was able to come up with a plan to manage the water so the exploration drilling could be completed. After pressure grouting in a cement collar casing, a blow-out- preventer (BOP – used to seal, control, and monitor water to prevent blow outs and the uncontrolled release of high-pressure water) and rock pack were installed successfully, shutting the water in. Most instances where that amount of water is encountered play out quite differently. Everyone has experienced, or knows someone who has, a situation where a high volume of water blows all your tooling out of the hole, resulting in a complicated mess.

Other examples of unexpected challenges include creative solutions using Boart Longyear’s own engineered underground rigs on the surface. The Drilling Services Underground Coring division mobilized rigs to a mine site where a delay in underground diamond coring exploration had the underground rigs idle on the surface. Someone saw the rigs waiting and asked if the idle underground rigs could drill flat-angled holes on the surface. Accepting the challenge, the underground coring rigs have been drilling these low, flat-angled boreholes ever since.

The mine site has a limited surface disturbance permit – which means that to reach the geological formations outside the area of their disturbance permit, Boart Longyear’s Underground Coring division is operating underground rigs on the surface to drill low-angled and flat holes that surface rigs often can’t reach because of their truck-mounted tall masts.

The underground rigs can drill at low angles from -40 degrees down to flat. They drill underneath the area where the mining client isn’t allowed to disturb the surface. This means exploration coring can follow ore veins without disturbing the surface and drill beneath the area outside of the issued disturbance permit.

The boreholes are 2600 ft to 2700 ft (792.48 m to 822.96 m) at a -40 to -12 degree angle. Boart Longyear has the tooling and the expertise for that type of drilling but was unable to accomplish the job with surface rigs because when set up flat, you’re going to be 12 ft (3.66 m) off the ground because the mast is way up on a truck carrier. With the underground rigs, a work platform or deck was constructed, which enabled the team to work right up close to them.

The Boart Longyear Drilling Services Underground Coring division in the US runs all Boart Longyear-engineered and manufactured LM and MDR rigs. The LM series of rigs feature easily interchangeable components, allowing for space constraints without sacrificing depth requirements. These modular coring rigs offer easier access in tight underground spaces and mobility for easier moves from hole to hole or shaft to shaft. Boart Longyear’s patented tooling offers safer and more efficient up-holes at any angle.

The underground coring rigs in the Drilling Services’ fleet are modified and customized, as compared to the commercially available Boart Longyear underground coring rigs. For example, the LM90 is souped up with a 150-horsepower engine instead of the typical 90-horsepower engine and includes additional modifications for increased depth capacity and core size.

The Drilling Services Underground Coring division has the experience and technical expertise to drill dewatering galleries, geotechnical borings, tunnel investigations, grouting services, and utility borings. The division also has experience with overcore drilling to measure in-situ stress. Overcore drilling involves drilling a hole to depth with a small diameter EX- or AX-sized bit, placing a probe to measure strain response data, and then using a special resin to glue the probe in place. After drilling out a larger diameter core to retrieve the probe, the overcore sample and probe are used for stress testing the rock formation to plan for ground support. This method is often used in both horizontal tunnels and vertical shafts to measure the amount of stress the rock can take.

Another unique application for underground rigs and crews is drilling on the surface into high walls for dewatering purposes. Flat to close-to-horizontal boreholes – from 10 degrees up to 10 degrees down – can be used to create self-draining dewatering boreholes in high walls. Pressure grouting in a cement collar casing keeps the hole from collapsing and can be used with a BOP valve in case the mining client wants to shut the water in the rock formation.

To maintain the integrity of the hole, installing slotted polyvinyl chloride (PVC) keeps the hole from collapsing. If you go through a broken zone, when water starts flowing, the hole can bridge off after a couple of months. The PVC keeps the hole open and the water running.

The benefit of using underground rigs for this type of drilling is the difference between large rotary rigs that produce chip samples and use lower rotation per minute (rpm) and higher torque whereas a coring rig operates at higher rpms and less torque. Chuck-drive underground coring rigs drill slower, straighter, and deeper and collect core for further analysis.

Geologists can use core samples from horizontal drilling into a high wall to look for fractures, faults, and oxidation (to identify water-bearing zones). They can also be identified in chip samples using rotary drilling rigs, but it’s more difficult to see them that way. A core sample provides a better physical view of the rock formation. Drilling high walls with underground coring rigs accomplishes two goals with one borehole – dewatering and obtaining core samples for assaying for fractures, faults, and oxidation.

LM90 with customized feed frame. Expert drillers from left to right: John Sanchez, Jimmie Maggard, Marcus Woody, and Sal Renteria.

Whether it’s an underground coring project or a surface application for underground coring rigs, the drilling crews are the real heroes at Boart Longyear. They have wide-reaching (global) resources to find unique and inventive solutions for complex, technical, and sometimes immense drilling challenges and they’re not afraid to ask questions.

More than just a can-do attitude, great work ethic, diverse skills, vast experience, technical knowledge, and a commitment to safety and each customer’s success, they get the job done. Drillers, driller assistants, welders, mechanics, supervisors, and other support personnel travel to work in remote locations, in all kinds of challenging weather, climates, and altitudes, all while spending extended time away from their families. The work is strenuous, involves extensive training, and requires their full attention for safety’s sake.

These real heroes all contributed to Boart Longyear’s latest safety achievement of 10 million man-hours and one year of being lost-time injury-free. A big congratulations to all the drilling crews and support personnel on this company-wide accomplishment! Denis Despres, Chief Operating Officer stated, "On a site level, we value the everyday procedures from standardized pre-start information meetings that focus on daily job tasks and associated hazards and risks, our online data management system, including the system’s mobile app, and the daily team and individual-based field level risk assessments. At Boart Longyear, it is everyone’s responsibility to work safely."

Originally published in Issue 11 of Coring Magazine, November 2019

The MDR700 is the first and only underground coring mobile drill rig with an on-board rod handler. The risk of hand and back injuries associated with handling rods is significantly reduced on the MDR700. The rod handler sets new standards for ease-of use, versatility, and most importantly, safety. The rod handler isolates the driller from the hazards of manual rod handling.

The mobility of the new MDR700 is a time-saver when moving from hole-to-hole using an agile Manitou diesel-powered four-wheel drive carrier. In a study where the rig was moved 500 meters (547 yards), the average time to move the MDR700 rig from hole-to-hole proved to be 80% faster than a regular underground exploration rig.

The next generation design of the integrated positioner and turntable offers extremely wide drilling angles and impressive reach to make positioning and drilling a series of holes easier. The rig features sophisticated articulations with eight movable joints so you can drill 270 degrees horizontally and vertically up to vertically down. The MDR700 also allows you to drill in a spherical manner without having to reposition the unit.

The Drill Control Interface (DCi) provides semi-automation and a fully electronic interface to safely and efficiently operate both the rod handler and the drill. The DCi is a substantial step for increased safety on-site by moving the driller away from moving parts and hydraulic hoses – isolating the driller from the hazards.

Set-up is quick and easy with the fully hydraulic positioning system and handheld remote controller. The MDR700 moves are faster and easier with the four-wheel drive diesel engine-powered Manitou carrier. Operating the MDR700 and the rod handler is smooth and easy when paired with the DCi. And the MDR700’s maintenance-friendly layout provides easy access for hydraulic servicing.