WireCo has introduced the UNION Gladiator Shield protection system, a patent-pending solution engineered to safeguard shovel hoist ropes from rock damage and abrasion in surface mining operations.
Designed for use with WireCo’s Tuf Max and Gladiator Hoist Ropes, the Gladiator Shield protection system is applied to the rope section directly above the dipper, the area most exposed to falling debris during loading. Its function is to defend this vulnerable section from rock strikes and surface wear that can prematurely age a rope and trigger costly unplanned outages. The Shield protects the polymer and outer wires to help extend rope longevity; it is available in diameters from 2-1/4 in to 2-7/8 in for high-performance hoist rope systems.
“Customers have pointed out for years that the section of rope over the dipper takes a beating from rockfall. Our Gladiator Shield protection system addresses that challenge head-on with a practical, factory-installed layer of protection,” said Mark Blankenship, Mining Product Manager at WireCo. “By protecting the rope where damage happens most often, we are helping mines improve rope life and reduce costly, unplanned downtime.”
Field trials at a US mine using UNION Gladiator Hoist Rope showed noticeable improvements in the rope spans protected by the Gladiator Shield protection system, supporting longer service life and more reliable shovel performance in critical applications. In an industry where average shovel downtime is estimated at $22,000 per hour, even modest gains in rope durability can translate quickly into avoided costs. With hoist rope sets costing between $20,000 and $30,000, the Shield represents a small incremental investment that can pay for itself in less than an hour of avoided downtime.
“Since implementing Gladiator Shield with our hard rock ore mining customers, we have seen a significant reduction in rope damage at the bale, historically one of the highest wear points,” said a Mining Distribution Manager of WireCo products. “Customers are now experiencing longer service life and fewer unexpected rope changes, resulting in reduced downtime and lower operating costs.”
The Gladiator Shield rock protection system was developed after on-site evaluations highlighted recurring damage at the dipper/bucket interface caused by rockfall and abrasion. In the past, mine operators attempted to solve this problem with cumbersome homemade methods such as sheet metal wraps or heavy clamps. By contrast, WireCo’s factory-installed solution is faster, safer and more effective.
Now at the patent-published stage in the United States, the Gladiator Shield protection system demonstrates WireCo’s commitment to investing in original engineering that addresses long-standing industry challenges. The company is also evaluating other potential applications for the technology, including static locations on shovels and draglines that experience high abrasion.
“Safety and productivity go hand-in-hand,” Blankenship added. “Every time you cut down the risk of a rope failing early at the bail, you’re not just keeping crews safer, you are also keeping production on track.”
