Todd Versteeg
In South Florida, the Mears Group Inc. team is tackling some of the most challenging conditions for underground utility work. Coral rock, a dense and abrasive material found throughout areas like Coral Gables and downtown Miami, consistently tests the capabilities of horizontal directional drilling (HDD) contractors.
For decades, Mears has been a trusted provider of underground energy infrastructure, offering engineering, construction and maintenance services across North America. Its teams work on critical systems such as natural gas pipelines, electric power transmission and telecommunications networks, supporting communities with reliable energy and connectivity.
The Miami-based Mears team primarily focuses on natural gas distribution line work, including installing service laterals, installing meters and conducting relights. These projects rely heavily on HDD to minimize surface disruption, particularly in densely populated neighborhoods. Precision and efficiency are essential, especially in urban areas where existing utilities, tight spaces and public impact must all be managed carefully.
However, beneath Miami's surface, coral rock formations pose unique challenges. These demanding conditions have become a defining aspect of the Mears team's operations, requiring innovative approaches to maintain project momentum.
Coral rock, drilling impact
South Florida's coral rock formations are unlike the sandy soil found in the northern parts of the state. These dense, fossilized structures create significant wear and tear on HDD equipment. The rock's unpredictable nature – varying in hardness, porosity and composition – further complicates drilling efforts.
“Coral rock is one of the toughest materials we deal with," said Blas Riesgo, Mears' director of South Florida operations. "It's dense, abrasive and unpredictable. You never know what you'll encounter when drilling through it.”
The abrasive qualities of coral rock cause rapid equipment wear, often leading to broken drill bits or damaged housings.
“When a bit snaps, you lose steering control immediately,” explained Jose Diaz, an HDD supervisor with over 25 years of experience. “Crews have to pull back the entire drill stem, retrieve or replace the broken components and sometimes excavate to make repairs. It's a costly and time-consuming process that disrupts our productivity.”
The challenges go beyond HDD tooling damage. Drilling in South Florida's urban environment often means navigating crowded underground spaces filled with existing utilities. Gas lines must maintain a consistent depth of 3 to 4 feet, requiring precision to avoid other infrastructure. Sharp steering adjustments, combined with the pressure of coral rock, place additional stress on tooling. For the Mears team, balancing the demands of coral rock and urban constraints has been a persistent challenge.
Additionally, the unpredictable porosity of coral rock complicates the use of drilling fluids, which can seep into the porous material. This adds an extra layer of complexity, requiring crews to carefully monitor pressure and adjust fluid use in real time. These combined factors make South Florida one of the most challenging environments for HDD contractors.
When bit failures and equipment damage began to significantly affect operations, Mears turned to its Vermeer Southeast dealership for assistance. As a long-time HDD equipment and tooling partner, the dealership worked closely with Mears to assess the needs. Recognizing the scale of the challenges posed by coral rock, the dealership brought in the Vermeer Cutting Edge team to develop a specialized solution.
“Our team explained the difficulties of working in coral rock and how it was slowing us down,” said Riesgo. “The Vermeer team listened and brought in the right people to help us address the problem.”
The collaboration resulted in the Bit Boss system, a retention solution designed to improve bit performance and reduce failures in harsh drilling conditions. The development process involved direct feedback from Mears' crews, ensuring the final product was tailored to their specific challenges.
How it works
The Bit Boss system enhances bit retention by incorporating three additional shoulder screws into the standard six-bolt design. This adjustment increases strength and reduces the likelihood of bits shearing under pressure. For the Mears team, this meant fewer breakdowns, faster repairs and more consistent productivity.
The system also simplified maintenance. In the rare case of failure, the design enabled crews to salvage housings and replace worn components without significant downtime. "We tested it on some of our toughest jobs," said Riesgo. "It worked better than we expected and has become a key part of our operations."
Diaz highlighted how the system immediately changed day-to-day operations. “Before, we replaced bits frequently because bit mounting bolts could not handle the stress under torque when drilling in coral rock,” he said. “Now, we only replace them when they wear out naturally. It's been a huge improvement.”
The Bit Boss system also improved operations in urban environments, where delays could have broader ripple effects on surrounding communities and businesses. With fewer equipment failures, the Mears team was able to focus on completing projects efficiently and keeping schedules on track.
To maximize the efficiency of the HDD operations, the Mears team standardized its tooling setup across its rigs to maintain consistency across their equipment.
"We try to standardize our HDD tooling across most of our crews," explained Riesgo. "This consistent setup has made it easier to train operators, helps reduce downtime and streamline inventory management."
Standardizing the tooling setup has also improved productivity in a region like South Florida, where unexpected conditions are common. Crews can rely on familiar equipment configurations and focus on the challenges posed by coral rock and crowded underground environments.
Learning from challenges
For utility contractors, South Florida's coral rock remains one of the toughest challenges to overcome. The Mears team's experience highlights the importance of collaboration and adaptability in addressing these conditions. By working closely with the dealer and the Vermeer Cutting Edge team, Mears was able to find a solution that not only reduced downtime but also improved overall efficiency.
The lessons learned in South Florida also have broader implications for the HDD industry. As urban environments become increasingly complex, the need for specialized tooling and collaborative problem-solving will only grow. The Mears team's ability to adapt and innovate offers a blueprint for overcoming harsh drilling conditions, even in the most demanding projects.
“Mears brought us the challenges they were facing, and we were happy to help them find a solution,” said Cody Mecham, a Vermeer product manager. "Seeing these improvements make a real difference in the field is always rewarding.”
With the Bit Boss system fully integrated into its operations, the Mears team continues to set the standard for HDD work across South Florida. Its ability to deliver results despite the region's challenging conditions demonstrates the importance of teamwork, innovation and a commitment to solving problems in the field. Combining local expertise with advanced tooling shows that even the toughest obstacles can be overcome. UI
About the author: Todd Versteeg is a public relation consultant from Des Moines, Iowa.
FOR MORE INFORMATION:
Mears Group, Inc., (832) 634-2900, mears.net
Vermeer, Vermeer Corporation - Industrial & Agricultural Equipment
