Manual de Fallas

TOP HAMMER TOOLS
FAILURE ANALYSIS GUIDE

TOP HAMMER TOOLS
Foreword 5
Button bit failures 6
Cross bit failures 10
Extension rod failures 13
Guide tube failures 17

Tube failures 20
Shank adapter failures 22
Coupling sleeve failures 27
Tapered rod & integral failures 29
Photo appendix 34
© Sandvik Mining and Construction Tools AB

ROCK DRILLING TOOLS
Sandvik rock drilling tools are engineered to give optimal long-life

performance under hard drilling conditions. Our customers’ as-
sociate Sandvik tools with high performance and reliability. On rare
occassions manufacturing errors can compromise the service life of
our tools and lead to premature failure.
Most of the failures are however a direct result of improper wor-

king practices or incorrect service. In the vast majority of cases it is
operating procedures or field conditions that are causing the failure.
It is suggested that the following be inspected for correct operation
before considering product defects.
• Rig settings
- Percussion pressure
- Feed pressure
- Rotation pressure and speed
• Flushing
• Lubrication
• Material handling, including proper bit grinding
Hole misalignment through poorly serviced rigs, bad collaring and

wandering holes are the foremost factors contributing to stress in the
drill string and subsequent tool failure. It is imperative that all reaso-
nable measures are taken to drill straight holes.
Sandvik tools are designed and manufactured within strict tole-

rances. Any mixing with competitors products can jeopardise their
integrity. Cemented carbide failures are generally the result of poor
grinding procedures or continuing to drill with excessive wear flats
on the inserts. The use of dated or incorrectly serviced grinding
equipment can grind bits outside their specified tolerances.
It is important to check grinding practices to ensure that they are

carried out in a competent manner. On many occasions it has been
observed that dry grinding wheels have been used for wet grinding
which will almost certainly lead to carbide failure. In non-wearing
rock formations ‘snakeskin’ fatigue is a primary factor in carbide
failure if regular grinding intervals are not employed.
This guide illustrates the main types of failure in rock tool products.
Listed with each type of failure are the probable causes of the failure
and some recommended actions to prevent further problems. If the
failure type or cause cannot be found within this guide it is reccom-
mended that you contact a Sandvik representative.
« List of content
A. BUTTON BIT FAILURES

Failure mode Probable cause Recommended action
A:1 BODY WASH Excessive flushing volume Reduce flushing volume
Drilling with excessive flushing Shorten grinding intervals

volume can in some rock cause
sand-blasting of the steel and
too big protrusion and breakage
of the buttons
Photograph »
A:2 SPLIT SKIRT Drilling with the thread open Increase feed force. Tighten
joints before percussion.
Wrong procedure when loose- Loosen bit with impact mecha-

ning the bit nism while seated firmly on face
or at bottom of hole. Use little
feed and no rotation, or use spe-
cial wrench.
Drilling with too worn threads Change to new rods. Make sure
specified rods are used.
Photograph »
Error code B2
A:3 STEEL CRACK Final failure when drilling a bit Change to bit with other design.
BETWEEN BUTTON- with big buttons (Heavy Duty)
in non wearing rock like limesto-
OR FLUSHING HOLES ne
Manufacturing error. Inferior but- Return for analysis.

ton hole-drilling precision
Photograph »
Error code F1f
6
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A:4 STEEL CRACK STAR- Steel fatigue Normal final failure with long
TING FROM A BUTTON service life
HOLE BOTTOM The bit is worn out.
Manufacturing error. Return for analysis.

Inferior button hole-drilling
precision
Error code F1b Photograph »
A:5 SKIRT RING-OFF Excessive rotational speed app- Apply minimal amount of ham-
lied to stuck bit mer pressure to free bit before
increasing rotation speed.
Bad collaring practices Reduce percussion and feed

when collaring.
Corrosion Improve storage practices. Neu-

tralise flushing agent.
Hammering on bit to break con- Loosen bit with impact mecha-

nection nism while seated firmly against
the rock. Use little feed and no
rotation, or use special wrench.
Excessive back hammering Use retrac bit.
Too low rock resistance Reduce impact power.

Error code B1
Fatigue Normal failure with long life
Photograph »
A:6 LOST BUTTONS Free hammering Do not engage full percussions

unless the bit is firmly seated
againts rock. Use reduced
percussion when collaring on
uneven surfaces.
Inadequate feed pressure Increase feed pressure.
Scaling with bit Use proper scaling tool.

Error code L1
Incorrect size correlation bet- Return for analysis.
ween button and button hole
Photograph »
7
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A:7 SNAKESKIN OR MICRO- Drilling in non-abrasive rock Earlier regrinding even if there
CRACKS IN CEMENTED creates micro-fractures in the are no or small wear flats
carbide sometimes looking like
CARBIDE snake skin.
The rock leaves a shiny surface Use a softer carbide grade.

on the buttons and a fatigue in
the surface of the cemented car-
bide, leading to button failure.
Photograph »
Error code S9
A:8 BUTTONS SHEARED- Excessive button protrusion Shorten grinding intervals.

OFF UNDER BODY through incorrect grinding or
steel wash. Protrusion greater
LEVEL than 3/4 of the button diameter
may not provide sufficient sup-
port to resist the tensile forces
that the button may encounter.
Incorrect size correlation bet- Return for analysis.

ween button and button hole
Photograph »
Error code S7u
A:9 BUTTONS CRUSHED Bad collaring practices Ensure the boom is secure. Start
INSIDE THE BIT BODY collaring with reduced impact,
then full pressure once bit is em-
bedded 300 mm in the rock.
Anti-taper from abrasive rock Grind bit to original shape.
Excessive button protrusion Ensure correct grinding proce-

from incorrect grinding. Button dures.
protrusion greater than 3/4 of the
Error code S4u button diameter will not provide
sufficient support to resist the
Photograph »
tensile forces that the buttons
may encounter.
8
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A:10 BUTTON CHIPPED Overdrilling Shorten grinding intervals.

Regrind when the wear flats are
max. 1/3 of the button diameter.
Snakeskin. Overdrilling in soft, Regularly inspect the bits and

non-abrasive rock leaves a shiny grind to remove micro-cracks
surface on the buttons. from the surface of the carbides.
Button carbide is too hard. Choose softer or tougher grade

of carbide.
Error code S3 Button not in contact with virgin Increase rotation speed.
material on impact
Photograph »
A:11 BUTTONS CRUSHED Snakeskin. Overdrilling in soft, Regularly inspect the bits and
DOWN TO LEVEL OF BIT non-abrasive rock leaves a shiny regrind regularly although the
surface on the buttons and a buttons seem not worn, just po-
BODY fatigue in the surface of the lished, to remove micro-cracks
cemented carbide, looking like from the surface of the carbides.
snakeskin
Overdrilling Shorten grinding intervals.
Incorrect grade of carbide Change carbide grade.

See product catalogue or bit se-
lection guide.
Error code S4 Incorrect grinding procedures Dry grinding can result in sna-
keskin fatigue. Employ wet
grinding.
Photograph »
A:12 BUTTON CRACKED Overdrilling Regrind when the wear flats are
max 1/3 of the button diameter.
Snakeskin Regularly inspect the bits and

grind to remove micro-cracks
from the surface of the carbide.
Incorrect grinding procedures Dry grinding can give snakeskin

fatigue. Employ wet grinding.
Button carbide is too hard Choose softer or tougher grade

of carbide.
Error code S1
Photograph »
9
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A:13 TOP OF BUTTON Overdrilling Shorten grinding < 1/3 D

SHEARED OFF LEVEL intervals. Regrind
when the wear flats
WITH BODY are max 1/3 of the
button diameter.
Drilling into metal Ensure correct drilling practices.
Snakeskin Regularly inspect the bits and

grind to remove micro-cracks
from the surface of the cemen-
ted carbide.
Error code S7 Excessive button protrusion Shorten grinding intervals.

through incorrect grinding.
Protrusions greater than 3/4
of the button diameter will not Photograph »
provide sufficient support to
resist the tensile forces that the
buttons may encounter.
B. CROSS BIT FAILURES

B:1 SPLIT SKIRT Taper mismatch or worn taper Use a taper gauge to check ta-
(taper bits) per angle. Change to proper bits.
Removing a bit with a hammer or Utilise a proper knock-off block

miner’s wrench when removing bit.
Error code B2
10
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B:2 TRANSVERSAL CRACK Overheating from improper Regrind bit to its original shape.
grinding Follow proper bit grinding proce-
dures.
Anti-taper from abrasive rock Shorten grinding intervals.
Grinding scratches due to wrong Check grinding procedures and

grinding wheel grinding wheel.
Photograph »
Error code S1
B:3 LONGITUDINAL CRACKS Overheating from improper Regrind bit to its original shape.
grinding Follow proper bit grinding proce-
dures.
Carbide grade too hard Select a bit with a softer, tougher

grade of carbide.
Photograph »
Error code S5
B:4 WHOLE INSERT LOST Brazed joint fatigued Normal failure with long life.
Inadequate feed pressure Increase feed pressure.
Braze failure Return for analysis.
Photograph »
Error code L1
11
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B:5 SKIRT RING-OFF Taper mismatch or worn taper Use a taper gauge to check ta-
(taper bits) per angle. Change to proper bits.
Drilling with a broken taper Change bit. Change to new drill

steel and refurbish.
Removing a bit with a hammer or Remove bit using correct knock-

miner’s wrench off tools.
Spinning Adjust feed force.
Excessive wear of the skirt (over-

drilled bit)
Error code B1
B:6 INSERT CORNER Pinching by drilling into a hole Colour code bits by size to re-
FRACTURED that was drilled with a smaller bit duce the risk for negative gauge
clearance.
Sharp corners or antitaper after Ensure proper grinding proce-

grinding dures.
Removing a bit with a hammer or Lower rotation and reduce ham-

miner’s wrench mer pressure.
Drilling conditions creating sna- Early regrinding even if there are

keskin no wear flats.
Bad collaring practices Reduce percussion and feed

Error code L2 when collaring.
Photograph »
B:7 INSERT SHATTERED Incorrect grade of carbide Change carbide grade, see pro-
duct catalogue.
Insufficient flushing Increase flushing pressure.
Improper grinding Ensure proper grinding proce-

dures.
Error code S4
12
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C. EXTENSION ROD FAILURES

C:1 SURFACE LAYER OF Surface damage caused by worn Replace centraliser.

STEEL COMPROMISED out centraliser bushings
BY A NICK OR DENT, Presence of a shiny steel surface
FATIGUE ROSE near rose suggests martensite
ORIGINATING FROM build up caused by rotation a-
THE SURFACE gainst steel
No centraliser used Ensure proper maintenance of

rig.
Using a sledge hammer on stuck Use a rod wrench to loosen.

steel
Improper care and handling Store rods in a rack when retrac-

ting drill string. Do not drop rods
or store on the ground.
Wandering or drifting hole Employ guide tools and ballistic

button bits.
Excessive feed Monitor feed pressure and tune

Error code Kxxu/Nxxu to rock conditions.
Bending due to misalignement Utilise alignment instruments

to monitor hole orientation once
then hole has been collared.
Replace wear pads on feed.
Make sure boom is stable under

drilling and rig is fixed.
Avoid sagging rods when drilling

horizontal holes. Consider using
a travelling centraliser.
Poor drilling conditions. Drilling Adjust drilling pressures and

in voids, seams and/or broken tune to rock conditions.
conditions
Avoid getting stuck in hole by
adjusting drilling pressures and
tune to rock conditions.
Use Retrac bits.
Feeder damaged when scaling Check feeder is not bent or

in drifting and tunneling twisted.
Photograph »
13
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C:2 ROD BREAKAGE Corrosion caused by corrosive Ensure that proper storage prac-
CHARACTERISED BY A flushing agents tices are being followed.
Change components more
FATIGUE ROSE frequently or neutralise flushing
ORIGINATING FROM agent.
THE FLUSHING HOLE
Insufficient rust protection Return for analysis.
Pores in flushing hole surface Return for analysis.
Photograph »
Error code Kxxi/Nxxi
C:3 PITTING OR WEAR IN Overheated threads due to loose Tune percussion and feed pres-
THE THREADS connection or hole deviation. sures to conditions (in most ca-
Reflected percussive energy ses reduce percussion pressure
and increase feed pressure).
Use a ballistic button bit to help
tighten drill string.
If caused by hole deviation take
steps to drill straighter holes.
Free hammering Do not engage full percussion

against rock. Use reduced
uneven surfaces.
Worn threads Replace worn components. Do

not put a worn rod on a new rod.
Change all rods together.
Driling with worn bits Regrind the bit when the wear
flats are max. 1/3 of the button
diameter.
Photograph »
Error code A11
14
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C:4 FAILURE AT THE BE- Wandering or drifting hole Employ guide tools and ballistic
GINNING OF THE button bits.
THREAD OR WHERE Worn threads and/or coupling. Replace worn components. Do
THE COUPLING ENDS M/M rods: migrating coupling not put a worn coupling on a
(bridge worn out) new rod. Change couplings
and rods together.
Bending due to feed overpres- Reduce feed pressure.

sure
Bending due to misalignement Utilise alignment instruments to

monitor hole orientation once the
hole has been collared.
Replace wear pads on feed.
Heavy rotational loads caused Regrind the bit when the wear
by drilling with a worn bit giving flats are max. 1/3 of the button
high reflected energy diameter.
Poor drilling conditions Adjust drilling pressures and

tune to rock conditions.
Use Retrac bit.
Continued percussion with stuck Activate anti-jamming when dril-

Error code Kxx rod ling.
C:5 CHIP BROKEN OFF Inadequate feed pressure Adjust pressure to conditions.
MALE THREAD
Worn coupling Replace worn components. Do
not put a worn coupling on a
new rod.
Misalignement of rods with Align drilling components with

extension. Steel hitting coupling extension.
shoulder
Drilling with worn bits Maintain button bits in time.
Corrosion fatigue due to corro- Replace rod. Treat water.

sive flushing water
Photograph »
Error code B4
15
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C:6 FAILURE ACROSS Hole deviation or feed misalig- Employ guide tools and ballistic
FEMALE THREAD nement button bits.
SECTION Inadequate feed pressure. Star- Monitor feed pressure and tune
ting point pittigs on thread to conditions.
Regrind the bit when the wear

High torque from drilling with flats are 1/3 of the button dia-
worn bits meter.
Ensure all components are

Mismatching threads Sandvik manufactured. Do not
”mix and match”.
Avoid hammering on connection.

Nick or dent in steel surface Use a wrench to loosen joints.
Employ proper care and hand-
ling procedures.
Photograph »
Error code B1
C:7 FEMALE END IS Tread joint not firmly tightened Make sure threads are tight be-
CHIPPED, CRACKED fore engaging percussion.
AND/OR FLARED
Misalignement of rods. Steel hit- Align drilling components with
ting coupling shoulder extension. Check and address
any issue of hole deviation
Photograph »
Error code B4
16
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C:8 LONGITUDINAL Worn out threads Replace components in time.

CRACK IN FEMALE
Hole deviation Take action to drill straighter
CONNECTION holes.
Misalignement of rods. Steel hit- Avoid excessive back hamme-

ting coupling shoulder ring.
Drilling with loose thread joints Increase the feed force.
Make sure that the joints are

tightened before percussion.
Align drilling components with

extension.
Photograph »
Error code B2
D. GUIDE TUBE FAILURES

D:1 FEMALE END IS Thread joint not firmly tightened Make sure threads are tight be-
CHIPPED, CRACKED fore engaging percussion.
AND/OR FLARED Misalignement of feed Service affected equipment.
Starting percussion or rotation Do not engage percussion or

with end of the shank resting rotation if shank thread is not
against the end of the coupling aligned inside coupling.
Photograph »
Error code B4
17
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D:2 FAILURE ACROSS MALE Inadequate feed pressure Monitor feed pressure and tune
THREAD SECTION to conditions.
Breakage starting from pitting on See D:3 below.

thread
High torque caused by drilling Regrind the bit when the wear
with a worn bit flats are 1/3 of the button dia-
meter.
Mismatching threads Ensure all components are

Sandvik manufactured. Do not
Nick or dent in steel surface Avoid hammering on bit. Employ

proper care and handling.
Worn threads Replace worn components.
Photograph »
Error code Kxx
D:3 PITTING OR WEAR IN Reflected percussive energy Adjust feed and percussion
THE THREADS pressures to the rock conditions.
Free hammering Do not engage full percussion

against rock. Use reduced
uneven surfaces.
Worn threads Replace worn components.
Drilling with worn bits Regrind the bit when the wear
flats are max. 1/3 of the button
diameter.
Photograph »
Error code A11
18
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D:4 LONGITUDINAL Worn out threads Replace components in time.

CRACK IN FEMALE
Misalignement of rods. Steel hit- Service affected equipment.
CONNECTION ting coupling shoulder
Hammering with open threads Always make sure that connec-

gives wedging effect which can ton is tight before hammering.
split the coupling
Avoid excessive back hamme-
ring.
Photograph »
Error code B2
D:5 BREAK IN TUBE BODY Surface damage caused by worn Replace centralisers.
out centralisers
Nick or dent in steel surface Avoid hammering on the tube.

Employ proper care and hand-
ling.
Photograph »
Error code Kxx/Nxx/B1
19
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E. TUBE FAILURES
E:1 PITTING OR WEAR ON Inadequate feed pressure and/or Adjust machine settings.
THREADS high percussion
Cuttings in thread Keep flushing on when breaking

pipe.
Corrosion caused by corrosive Change components more

flushing agents frequently or neutralise flushing
agent.
Photograph »
Error code A11
E:2 FAILURE IN MALE Misalignement of feed Make sure boom is aligned. En-
OR FEMALE THREAD sure good collaring practices.
SECTION Hole deviation Employ Retrac bits with ballistic
buttons.
Hit on thread Ensure good rod handling prac-

tices.
Corrosion caused by corrosive Change components more

flushing agents frequently or neutralise flushing
agent.
Photograph »
Error code Kxx/Nxx
20
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E. TUBE FAILURES
E:3 BREAK IN THREAD Corrosion caused by corrosive Change components more

CLEARANCE flushing agents frequently or neutralise flushing
agent.
Misalignement of tube during Return for analysis.

friction welding
Error code B1
E:4 BREAK IN TUBE Friction martensite from worn Change centraliser jaws.
out centraliser jaws
Misalignement of feed Make sure boom is aligned. En-

sure good collaring practices.
Hole deviation Employ Retrac bits with ballistic

buttons.
Nick on tube Ensure good rod handling prac-

tices.
Photograph »
Error code B1
21
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F. SHANK ADAPTER FAILURES

F:1 IMPACT MARKS, Misalignement due to worn out Replace worn components in
CHIPPED OR bushings rock drill.
RIVETED END Damaged piston Replace piston.
Service affected equipment.
Service rock drill.
Error code C2
Photograph »
F:2 FAILURE ACROSS Poor or no lubrication Ensure functioning lubrication

SPLINES
Wrong or contaminated shank Change to correct oil.
lubrication oil
Stuck rod in broken rock and/or Use Retrac bits and activate
excessive back hammering anti-jammig when drilling.
Worn out chuck coupling Replace worn components.
High rotational torque Adjust drilling pressures.
Overdrilling bits Regrinding should be done when

the wear flats are max. 1/3 of the
button diameter.
Inadequate feed pressure Monitor coupling temperatures

and adjust feed pressures accor-
ding to recommendations.
Error code Nxx
22
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F:3 WEAR ON BOTTOM OF Excessive rotation when retrac- Adjust rotation speed.
SPLINE SHOULDER ting string
(common in bench Stuck rod in broken rock Use Retrac bits and activate
drilling) anti-jamming when drilling. Use
a rock drill with power extractor.
Error code C3 Photograph »
F:4 FAILURE AT Misaligned boom Ensure boom is aligned when

FRONT HEAD drilling.
Misalignement from worn front Replace worn components.

bushing
Excessive feed Reduce feed pressure, tune to

rock conditions.
Error code Kxx/Nxx

Photograph »
23
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F:5 FAILURE IN THREADS Drilling with open threads cau- Adjust settings to balance im-
sing heat and pittings on thread pact, feed and rotation
Poor drilling conditions Adjust drilling pressures and

tune to rock conditions. Use
Retrac bit.
Misaligned boom Ensure boom is aligned when

drilling.
Mismatched threads Use original Sandvik compo-

nents.
Worn-out coupling Replace worn-out couplings.

Change couplings with new
shank adapters. Use a bridged
coupling sleeve.
Wandering or drifting hole Employ guide tools and ballistic

button bits.
Bending due to feed overpres- Reduce feed pressure.

sure
Bending due to misalignement Utilise alignement instruments to

monitor hole orientation once the
hole has been collared. Replace
wear pads on feed.
Heavy rotational torque caused Regrind the bit when the wear
by drilling with a worn bit giving flats are max. 1/3 of the button
high reflected energy diameter.
Continued percussion with stuck Activate anti-jamming when dril-

rod in broken rock ling.
Error code Kxx
Insufficient thread lubrication Use thread grease.
Photograph »
F:6 FAILURE AT FRONT Misalignement from worn front Replace worn components.
BUSHING bushing
Poor lubrication Ensure proper lubrication.
Error code Kxx Photograph »
24
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F:7 CORROSION Corrosion from corrosive Replace broken/damaged com-

flushing agent ponents. Change or neutralize
flushing agent.
Dirty flushing water Clean water of solids. Use large

water basins or install filters.
Fatigue Replace more frequent
Error code Kxx Photograph »
F:8 PITTING AND CHIPPING Not balanced impact and feed Monitor coupling temperatures
OF THREADS pressures and adjust impact and feed
pressures according to recom-
mendations.
Loose joint Use a Retrac bit with semi-bal-

listic buttons to tighten string.
Incorrect relation between feed Match feed and rotation speed

and rotation speed resulting in according to specifications.
screaming during threading
Insufficient thread lubrication Use thread grease.
Error code A11
25
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F:9 PITTING AND GALLING Poor or missing lubrication Make sure that rock drill is recie-
ON SPLINES ving sufficient lubrication
Excessive rotation in soft or Adjust drilling pressures.

broken ground
Incorrect shank lubrication oil Change to recommended oil.
Hydraulic oil is too hot Equip rig with a cooling unit.
Stuck rod in broken rock and/or Use Retrac bits and activate
excessive back hammering anti-jamming when drilling. Use
a rock drill with power extractor.
Error code C3
Photograph »
F:10 EXCESSIVE WEAR Inadequate feed pressure Adjust feed pressure according
ON TOP OF SPLINE to recommendations.
SHOULDER Worn-out rotation bushing Change bushing.
Damping piston is not functio- Repair damping piston.

ning
Error code C3 Photograph »
26
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F:11 CHIPPED THREAD END Adapter dropped into coupling Inspect feed for misalignement.
Machine cradle is too loose Secure good alignement.
Misalignement of boom
Adapter not properly coupled to Replace worn-out couplings.

drill steel. Use new couplings with new
shank adapters.
Broken drill rod Replace rod.
Drill steel end not square Check alignement or hole devia-

tion.
Error code B4
Photograph »
G. COUPLING SLEEVE FAILURES

G:1 IMPACT MARKS, Starting percussion or rota- Do not engage percussion or

CHIPPED END tion with the shank end resting rotation if shank thread is not
against the shoulder of the aligned inside coupling.
coupling
Misalignement of feed Service affected equipment.
Misalignement due to hole de- Take action to drill straighter

viation holes, eg. use a retrac bit, guide
rod etc.
Photograph »
Error code B4
27
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G:2 LONGITUDINAL CRACK Drilling with loose thread joints Increase the feed force. Make
sure that the joints are tightened
before percussion. Avoid exces-
sive back hammering.
Back rotation with precussion Do not back rotate.
Nick or dent in steel surface Avoid hammering on connection.

Rotate loose or use a wrench
to loosen joints. Employ proper
care and handling.
Worn-out sleeve Change sleeve.
Hole deviation Take action to drill straighter

holes, eg. use a retrac bit, guide
rod etc.
Photograph »
Error code B2
G:3 TRANSVERSAL CRACK Nick or dent in steel surface Avoid hammering on connection.
Rotate loose or use a wrench
to loosen joints. Employ proper
care and handling.
Worn-out sleeve Change sleeve.
Hole deviation or feed misalig- Employ guide tools and ballistic

nement button bits.
Inadequate feed pressure Monitor feed force and tune to

conditions.
Heavy rotational loads from dril- Regrind the bit when the wear
ling with worn bits flats are max. 1/3 of the button
diameter.
Mismatching threads Ensure all components are

Sandvik manufactured. Do not
Error code B1
28
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H. TAPERED ROD & INTEGRAL FAILURES

H:1 FAILURE IN THE Worn chuck bushing Replace worn bushing.

SHANK END
Lack of or improper lubrication Check that adequate volume of
shank lubrication oil is reaching
the shank.
Excessive feed pressure. Reduced feed pressure.
Flushing hole in shank incor- Return for analysis.

rectly manufactured
Error code Nxx
H:2 STRIKING FACE Worn chuck bushing Replace worn bushing.

DEFORMED
Damaged piston Replace piston.
High operating pressures Adjust to rock conditions.
Hardness heat treatment not to Return for analysis.

specification
Photograph »
Error code C2
29
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H:3 WEAR OR BREAKAGE Indentation of the collar by Replace worn bushing.

AT BEGINNING OF chuck bushing Ensure that Sandvik parts are
used.
COLLAR RADIUS
Overheating due to poor lubrica- Ensure adequate lubrication is
tion applied to shank.
Worn chuck bushing Replace worn bushing.
Incorrect radius in transition Return for analysis.

between collar and shank
Error code B1 Photograph »
H:4 BREAKAGE IN Drilling with bent rod Keep rod aligned.

ROD SECTION
Surface damaged Review handling routines.
Hit at corners Do not hit rods when stuck in

hole.
Error code Kxx/Nxx
H:5 SHANK WEAR OR COKE Worn chuck bushing Replace worn bushing.
BOTTLE WEAR
30
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H:6 BREAKAGE ON Worn bit socket. Change bit.

TAPER RADIUS
Using a damaged bit with a ridge Change bit or ream out ridge.
or lip within the socket.
Spinning Adjust feed force. Use Sandvik

bits, do not ”mix and match”.
Use bit with a symmetrical but-
ton design.
Error code B1
H:7 BREAKAGE CLOSE Drilling through the bottom of Improve working practices.
TO BIT END blocks.
Excessive gauge wear on Reduce service life.

gauge Resharpen bit when wear flats
are greater than 1/3 of button
diameter
Broken from flushing hole Return for analysis.
Error code Kxx
31
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H:8 FAILURE IN THE JOINT Poor brazing Return for analysis.
Photograph »
Error code L
H:9 FAILURE IN THE WING Quality issue Return for analysis.
Photograph »
Error code F
32
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H:10 FAILURE IN Improper grinding - too sharp Follow grinding instructions

THE CARBIDE insert corners
Overheating insert when reshar- Resharpen insert to its original

pening. shape. Follow proper grinding
procedures and use correct grin-
ding wheel.
Drilling conditions creating sna- Lower rotation and reduce ham-

keskin mer pressure. Early regrinding
even if no wear flats.
Antitaper Employ proper grinding routines
Photograph »
Error code S
H:11 PROPELLER WEAR Poor flushing Increase flushing pressure.
Poor rotation Increase rotation speed.
Photograph »
33
PHOTO APPENDIX
« List of content
A:1 BODY WASH
« Back
35
« List of content
A:2 SPLIT SKIRT
Error code B2
« Back
36
« List of content
A:3 STEEL CRACK BETWEEN BUTTON- OR FLUSHING HOLES
Error code F1f
« Back
37
« List of content
A:4 STEEL CRACK IN THE BIT BODY ORIGINATING FROM THE BOTTOM OF A BUTTON HOLE
Error code F1b
« Back
38
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A:5 SKIRT RING-OFF
Error code B1
« Back
39
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A:6 LOST BUTTONS
Error code L1
« Back
40
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A:7 SNAKESKIN OR MICRO-CRACKS IN CEMENTED CARBIDE
Error code S9
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41
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A:8 BUTTONS SHEARED-OFF UNDER BODY LEVEL
Error code S7u
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42
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A:9 BUTTONS CRUSHED INSIDE THE BIT BODY
Error code S4u
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43
« List of content
A:10 BUTTON CHIPPED
Error code S3
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44
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A:11 BUTTON CRUSHED DOWN TO LEVEL OF BIT BODY
Error code S4
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45
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A:12 BUTTON CRACKED
Error code S1
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46
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A:13 TOP OF BUTTON SHEARED OFF LEVEL WITH BODY
Error code S7
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47
« List of content
B:2 TRANSVERSAL CRACK
Error code S1
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48
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B:3 LONGITUDINAL CRACKS
Error code S5
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49
« List of content
B:4 WHOLE INSERT LOST
Error code L1
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50
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B:6 INSERT CORNER FRACTURED
Error code L2
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51
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C:1 SURFACE LAYER OF STEEL COMPROMISED BY A NICK OR DENT,

FATIGUE ROSE ORIGINATING FROM THE SURFACE
Error code Kxxu/Nxxu
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52
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C:2 ROD BREAKAGE CHARACTERISED BY A FATIGUE ROSE

ORIGINATING FROM THE FLUSHING HOLE
Error code KxxI/NxxI
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53
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C:3 PITTING OR WEAR IN HE THREADS
Error code A11
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54
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C:5 CHIP BROKEN OFF MALE THREAD
Error code B4
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55
« List of content
C:6 FAILURE ACROSS FEMALE THREAD SECTION
Error code B1
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56
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C:7 FEMALE END IS CHIPPED, CRACKED AND/OR FLARED
Error code B4
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57
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C:8 LONGITUDINAL CRACK IN FEMALE CONNECTION
Error code B2
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58
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D:1 FEMALE END IS CHIPPED, CRACKED AND/OR FLARED
Error code B4
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59
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D:2 FAILURE ACROSS MALE THREAD SECTION
Error code Kxx
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60
« List of content
D:3 PITTING OR WEAR IN THE THREADS
Error code A11
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61
« List of content
D:4 LONGITUDINAL CRACK IN FEMALE CONNECTION
Error code B2
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62
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D:5 BREAK IN TUBE BODY
Error code Kxx/Nxx/B1
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63
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E. TUBE FAILURES
E:1 PITTING OR WEAR ON THREADS
Error code A11
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64
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E. TUBE FAILURES
E:2 FAILURE IN MALE OR FEMALE THREAD SECTION
Error code Kxx/Nxx
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65
« List of content
E. TUBE FAILURES
E:4 BREAK IN TUBE
Error code B1
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66
« List of content
F:1 IMPACT MARKS, CHIPPED OR RIVETED END
Error code C2
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67
« List of content
F:3 WEAR IN BOTTOM OF SPLINE SHOULDER (common in bench drilling)
Error code C3
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68
« List of content
F:4 FAILURE AT FRONT HEAD
Error code Kxx/Nxx
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69
« List of content
F:5 FAILURE IN THREADS
Error code Kxx
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70
« List of content
F:6 FAILURE AT FRONT BUSHING
Error code Kxx
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71
« List of content
F:7 CORROSION
Error code Kxx
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72
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F:9 PITTING AND GALLING ON SPLINES
Error code C3
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73
« List of content
F:10 EXCESSIVE WEAR ON TOP OF SPLINE SHOULDER
Error code C3
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74
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F:11 CHIPPED THREAD END
Error code B4
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75
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G:1 IMPACT MARKS, CHIPPED END
Error code B4
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76
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G:2 LONGITUDINAL CRACK
Error code B2
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77
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H:2 STRIKING FACE DEFORMED
Error code C2
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78
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H:3 WEAR OR BREAKAGE AT BEGINNING OF COLLAR RADIUS
Error code B1
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79
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H:8 FAILURE IN THE JOINT
Error code L
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80
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H:9 FAILURE IN THE WING
Error code F
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81
« List of content
H:10 FAILURE IN THE CARBIDE
Error code S
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82
« List of content
H:11 PROPELLER WEAR
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83
www.rocktools.sandvik.com
Sandvik Mining and Construction Tools AB

SE-811 81 Sandviken, Sweden. Tel +46 26 26 20 00 Fax +46 26 26 23 00

Manual de Fallas

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TOP HAMMER TOOLS

FAILURE ANALYSIS GUIDE

FAILURE ANALYSIS GUIDE

Cross bit failures 10

Extension rod failures 13

Guide tube failures 17

Shank adapter failures 22

Coupling sleeve failures 27

Tapered rod & integral failures 29

© Sandvik Mining and Construction Tools AB

Sandvik rock drilling tools are engineered to give optimal long-life

Most of the failures are however a direct result of improper wor-

Hole misalignment through poorly serviced rigs, bad collaring and

Sandvik tools are designed and manufactured within strict tole-

It is important to check grinding practices to ensure that they are

A. BUTTON BIT FAILURES

A:1 BODY WASH Excessive ﬂushing volume Reduce ﬂushing volume

Drilling with excessive ﬂushing Shorten grinding intervals

Wrong procedure when loose- Loosen bit with impact mecha-

Manufacturing error. Inferior but- Return for analysis.

A. BUTTON BIT FAILURES

Manufacturing error. Return for analysis.

Error code F1b Photograph »

Bad collaring practices Reduce percussion and feed

Corrosion Improve storage practices. Neu-

Hammering on bit to break con- Loosen bit with impact mecha-

Excessive back hammering Use retrac bit.

Too low rock resistance Reduce impact power.

A:6 LOST BUTTONS Free hammering Do not engage full percussions

Inadequate feed pressure Increase feed pressure.

Scaling with bit Use proper scaling tool.

A. BUTTON BIT FAILURES

The rock leaves a shiny surface Use a softer carbide grade.

A:8 BUTTONS SHEARED- Excessive button protrusion Shorten grinding intervals.

Incorrect size correlation bet- Return for analysis.

Anti-taper from abrasive rock Grind bit to original shape.

Excessive button protrusion Ensure correct grinding proce-

A. BUTTON BIT FAILURES

A:10 BUTTON CHIPPED Overdrilling Shorten grinding intervals.

Snakeskin. Overdrilling in soft, Regularly inspect the bits and

Button carbide is too hard. Choose softer or tougher grade

Overdrilling Shorten grinding intervals.

Incorrect grade of carbide Change carbide grade.

Snakeskin Regularly inspect the bits and

Incorrect grinding procedures Dry grinding can give snakeskin

Button carbide is too hard Choose softer or tougher grade

A. BUTTON BIT FAILURES

A:13 TOP OF BUTTON Overdrilling Shorten grinding < 1/3 D

Drilling into metal Ensure correct drilling practices.

Snakeskin Regularly inspect the bits and

Error code S7 Excessive button protrusion Shorten grinding intervals.

B. CROSS BIT FAILURES

Removing a bit with a hammer or Utilise a proper knock-off block

B. CROSS BIT FAILURES

Anti-taper from abrasive rock Shorten grinding intervals.

Grinding scratches due to wrong Check grinding procedures and

Carbide grade too hard Select a bit with a softer, tougher

Inadequate feed pressure Increase feed pressure.

Braze failure Return for analysis.

B. CROSS BIT FAILURES

Drilling with a broken taper Change bit. Change to new drill

Removing a bit with a hammer or Remove bit using correct knock-

Spinning Adjust feed force.

Excessive wear of the skirt (over-

Sharp corners or antitaper after Ensure proper grinding proce-

Removing a bit with a hammer or Lower rotation and reduce ham-

Drilling conditions creating sna- Early regrinding even if there are