Vermeer Corporation received a unique request about a year ago.
A customer located in the Middle East needed to complete a critical horizontal directional drilling job but had a very specific need. The job called for rock reamers, dirt tooling and barrel reamers for maxi rigs — but there weren’t any tooling options that matched the specific job requirements. This presented a significant obstacle, as the customer’s project was at a standstill without the right equipment.
The challenge
The specifications the customer was looking for did not match any tooling that Vermeer currently manufactured. The specifications required were unprecedented for Vermeer. The tooling needed to be robust enough to get the job done, while still maintaining adequate mud flow. ATCO then got in contact with the Cutting Edge team at Vermeer to see if custom tooling was an option for this request.
After exploring all the necessary specs, it was time to try to figure out how to create these massive reamers.
Developing custom tooling
The first step to create customized tooling was to determine how to maintain the correct specs, while incorporating the necessary features to complete the drill shot. This was done by trading information and sketches between Cutting Edge engineer Jeremy Knepper and the customer.
“The customer was requesting specific technical specs that were outside the norm for our tooling. We experienced challenges to procure parts to match these specs, which made close collaboration between the factory and customer essential,” explained Cutting Edge sales manager Chris Fontana. “Another challenge we faced was to find the right parts at the right price, to create tooling at a cost that everyone was pleased with.”
After the sketches were approved, part numbers were created and orders were sent to the Des Moines, Iowa factory.
In terms of design, this order featured the most robust push-pull reamer Vermeer has ever developed, at 62 in (157 cm) in diameter and 16 ft (4.8 m) long. The weight of these reamers ranged from 3,000 lb – 6,000 lb (1,360 kg – 2,721 kg).
Agility at the Des Moines facility
Due to the unconventional size of these reamers, the Cutting Edge factory in Des Moines was involved in the project at the beginning. The Des Moines plant exclusively manufactures underground tooling but is accustomed to making changes on the shop floor to accommodate special tooling orders. Unlike other special orders, this tooling was so large and heavy, additional equipment, processes and support were required to do the work safely.
Even with all the adjustments and changes that happened within the Des Moines plant, the order was finished 30 days ahead of schedule. This speedy completion can be attributed to all team members who embraced agility, as well as Production Manager Nate Oostra. “Nate and the Des Moines manufacturing team had to be creative when building this tooling,” Fontana stated. “The length, weight and size of the reamers made it a challenge to build them safely. Our priority in the factory is team member safety, so that is always something we are focused on — no matter the product being built.”
Vermeer has always been committed to innovation. That innovation doesn’t stop, even when unconventional requests come in. By collaborating with ATCO and the Des Moines factory, the customer got the right tooling — and faster than expected. The Cutting Edge team and Des Moines team members pushed the boundaries of what they thought was possible, thanks to the dedication and agility of everyone involved.
If you encounter untraditional ground conditions, get in touch with your local Vermeer dealer to explore custom solutions.
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