A button bit is a drill bit whose cutting face uses multiple hardened “buttons” (typically tungsten-carbide) to fracture rock under impact and/or rotation. When we say rock button bits, we refer specifically to button bits engineered for rock-drilling applications — high hardness, abrasion, percussive impact. Because these bits are used in severe conditions, they are more prone to specific failure modes than bits used in softer materials.

1. Frequent Problems with Rock Button Bits

Here are the more frequent issues experienced in field operations:

1.1 Premature Wear and Tear of Buttons / Inserts

One common issue is that the buttons on the bit face wear down or flatten much sooner than expected. Reports indicate wear often arises from high abrasion in the rock, inadequate flushing, or excessive feed/impact pressure.

If the buttons become dull or flat, the bit’s efficiency drops — it takes more time and energy to fragment the rock.

1.2 Breakage, Chipping or Cracking of Buttons / Bit Body

Another frequent failure mode: buttons chip, crack or pop out; the bit body may crack under impact stress, or the gauge area may wear through. For example, one article notes “breakage and chipping are… often resulting from excessive pressure or from hitting a particularly hard or dense area in the rock.”

1.3 Inefficient Drilling / Slow Penetration

Sometimes the bit appears okay visually, but performance drops — penetration slows, churning instead of cutting. Causes include: bit–formation mismatch, poor flushing (cuttings not removed), bit bounce, or worn inserts.

1.4 Gauge Wear / Hole-Diameter Enlargement

The gauge section (outer diameter) of the bit is critical to maintain hole size and prevent deviation. When gauge buttons wear off or the body erodes, the bit may “walk”, hole diameter increases, flushing becomes less effective, and the bit’s life is reduced.

1.5 Poor Flushing & Cuttings Removal

Even a well-designed rock button bit will underperform if flushing (air, water, or mud) is inadequate. Cuttings stay in the hole, impairing bit contact with fresh rock, increasing heat, causing bounce and reducing bit life.

2. How to Avoid or Mitigate These Issues

Now that you know the problems and causes, here are actionable steps to reduce risk and improve bit life.

2.1 Match Bit to the Formation & Method

Before drilling, evaluate rock hardness, abrasiveness, jointing/voids.

Select rock button bits with appropriate button size/shape, face design, body metallurgy, gauge protection.

If conditions change mid‐job (harder zone, more abrasiveness), be ready to switch bit design.

2.2 Monitor and Optimise Drilling Parameters

Ensure feed pressure, hammer/impact settings (in DTH) or rotation speed (in rotary) are compatible with bit and formation.

Avoid over‐feeding—excessive pressure can chip buttons or crack body; under‐feeding may reduce efficiency and increase wear.

Monitor penetration rate: a sharp drop often signals bit wear or mismatch.

Keep vibration/bounce minimal: unstable drilling increases risk of button damage.

2.3 Ensure Effective Flushing & Chip Removal

Confirm air/water/mud flow meets design requirements for hole size and depth.

Regularly check for blocked flushing holes or rod/bit string that is not clean.

Lift and flush the string periodically if needed to remove cuttings.

Use proper hole cleaning technique and avoid allowing cuttings to accumulate.

2.4 Conduct Regular Inspection & Maintenance

At shift end or when penetration drops: inspect button face, gauge, body for wear, chips, cracks.

Retire or refurbish bits when wear reaches predefined threshold—not only when failure occurs.

Store bits properly: dry, stable environment, avoid impacts or stacking that damage carbide buttons.