Kelly Bars Piling Tools

Kelly Bar Manufacturing for Reliable Foundation Drilling

We are Kelly Bars Piling & Drilling Tools Manufacturer for rotary drilling rigs that transmit torque and crowd force from the drilling rig to the drilling tool, delivering consistent performance in demanding foundation and piling applications.

Our Kelly bars are high-strength ductile steel telescopic tubes with precision-manufactured drive strips, guide strips, pull-down keys, locking elements, and drilling tool connections. The telescopic design allows the Kelly bar to telescope in and out during drilling but still transmit the necessary torque and crowd force thru the entire assembly.

We have Kelly Bar Manufacturering for different rotary drilling rigs like Bauer BG-40, BG-36, BG-28, and BG-25. Custom configurations can be designed according to the drilling rig, required depth, torque, diameter, and application.

Need the right Kelly Bar for your drilling rig? Contact Falcon Core Industries for a technical quotation.

What Is a Kelly Bar?

Kelly Bar is one of the most important parts of a rotary drilling rig. It connects the rotary drive system of the rig to the drill bit, transmitting the mechanical forces required to drill thru soil, rock, and other ground formations.

The telescopic Kelly bar is made of several sections of steel that telescope into each other. As the drilling operation continues, sections are extended to the needed depth and retracted when the drilling tool is lifted.

The Kelly Bar has two major forces: Torque – The turning force required to rotate the drilling tool.

The outer section receives torque and crowd force from the rotary drive. The forces are progressively transmitted over the telescopic sections to the innermost section, which is coupled to the drilling tool by the drive stub.

This design enables rotary drilling rigs to reach considerable drilling depths with a compact transport and operating configuration.

Types of Kelly Bar

The correct Kelly bar setup depends on the drilling rig, the desired depth, the ground conditions, the torque requirements, and the drilling tool.

Interlocked Kelly Bars Interlocking Kelly bars are used to transmit torque and crowd force thru the mechanical locking of telescopic sections. They are designed for demanding drilling applications requiring high torque, controlled force transmission, and reliable engagement of the sections.

Typical applications are the following: Bored pile construction • Deep drilling for foundation • Foundations of bridges • Building foundations • Infrastructure Projects • Pile and diaphragm wall works • Large diameter drilling • Geotechnical constructions • Heavy civil construction • Projects in rotary drilling The correct configuration of the Kelly bar is a function of the rig and the particular drilling conditions. Drilling of deep foundations, Works for Pile, Densely packed soil formations, hard soil, Locking Things, Locking components engage the telescopic sections and transfer torque and crowd forces thru the entire Kelly bar. stub shaft. The lower drive stub makes the connection between the Kelly bar and the drill bit.

Kelly Bar Applications: Kelly bars are widely used in rotary drilling applications where control of torque and crowd force is to be transferred from the drilling rig to the tool.

Kelly Bars for Bauer Drilling Rigs: Falcon Core Industries supplies Kelly bar configurations compatible with selected Bauer rotary drilling rigs, including: • Bauer BG-40 • Bauer BG-36 • Bauer BG-28 • Bauer BG-25

An interlocking or friction configuration may be appropriate depending on the application.

Inspect the Tool Connection: The Kelly Bar shall be compatible with the drilling bucket, auger, core barrel, casing tool, or other drilling attachment being used. Kelly Bar Replacement and Custom Fabrications If your current Kelly bar is worn, damaged, cracked, or just not suitable for your drilling needs, changing it to a correctly engineered configuration can help restore drilling performance.

Description	Description Outer Dia(mm)	No. of Sections	Max Drilling Depth (m)	Torque (KN-m)	Drilling Rigs
HK 40/470/3	470	3	48	400	BG-40 / BG-36
HK 40/470/4	470	4	72	400	BG-40 / BG-36
HK 28/419/3	419	3	36	280	BG-28
HK 28/419/4	419	4	64	280	BG-28
HK 28/394/3	394	3	36	280	BG-28 / BG-25
HK 28/394/4	394	4	64	280	BG-28 / BG-25

Industries We Serve

We manufacture industrial auger for:

While in operation, the rotary gearbox applies torque to the outer portion of the Kelly Bar.
1. Drive strips transfer rotational torque between the telescopic sections.
2. Pull-down keys transfer the crowd force generated by the drilling rig.
3. Locking elements engage the adjacent inner section.
4. Torque and crowd force continue through the telescopic assembly.
5. The innermost section transfers the forces through the drive stub to the drilling tool.
6. The drilling tool rotates and advances into the ground.

This mechanical load path allows the drilling rig to efficiently transfer its available torque and crowd force to the tool at the bottom of the borehole.

Significance of Kelly Bar Design. A Kelly bar is subjected to repetitive cycling of • High torque • Compression (Axial) • Extension and retraction by telescope • Vibration • Loadings impact • Abrasive drilling conditions • Dynamic loading and misalignment

Correct dimensions, material selection, machining, welding, locking geometry, and rig compatibility are critical to Kelly bar performance and service life for this reason.

Kelly Bars Friction The Kelly bars are of the friction type, which transfer the torque by the friction between the telescopic sections. The downward drilling force is provided by the weight of the Kelly Bar and the drilling system. They may be suitable for applications where the ground conditions and drilling requirements do not require a mechanically interlocking configuration. Which Kelly Bar Should I Choose? The decision should be based on the following factors: Drilling Rig, Maximum Torque, Required Depth, Bore Diameter, Ground Conditions, and Drilling Tool. Falcon Core Industries can help you choose the right configuration, based on your equipment and project needs. Kelly Bar Mfg. A Kelly bar is subjected to high mechanical loads during rotary drilling.

So accuracy in manufacturing is critical to reliable operation. Falcon Core Industries concentrates on the key structural elements of the Kelly Bars Piling Tools Manufacturer consisting of Steel Tubes - High Strength The telescopic sections need strength and ductility to withstand repeated torque and axial loading. Strip Drive Drive strips are the mechanical interface needed to transmit rotary torque between one telescopic section and another. Guide Strips. The guide elements serve to provide controlled movement and alignment between the telescopic sections. Keys Drop-Down. The axial force generated by the rotary drilling rig The pull-down keys transfer the axial force generated by the rotary drilling rig to the drilling assembly. to the drilling assembly by means of the pull-down keys.

Our published configurations range from 394 mm to 470 mm outer diameter, with three- and four-section options and maximum drilling depths of up to 72 meters in the listed configurations. If you require a replacement Kelly bar or a new configuration for a Bauer rig, provide us with the exact machine model, and we can evaluate the appropriate Kelly bar specification.

Our team can assess your needs and recommend a Kelly Bar configuration that best suits you.

Request Technical Quote: Falcon Core Industries Al Sajaa Industrial Area, Sharjah, U.A.E.
Phone: +971 6 579 5864 Email: info@falconcoreind.com