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WireCo has introduced the UNION Gladiator Shield, a patent-pending protection system designed to extend the life of shovel hoist ropes in surface mining operations by reducing rock damage and abrasion.
The Gladiator Shield is applied to the rope section directly above the dipper, an area frequently exposed to falling debris during loading. The system is available in diameters from 2-1/4 inches to 2-7/8 inches and is compatible with WireCo’s Tuf Max and Gladiator Hoist Ropes. By defending the polymer and outer wires, the Shield helps extend rope service life and reduce unplanned outages.
“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 U.S. mine using UNION Gladiator Hoist Rope showed improved performance in the spans protected by the Shield, supporting longer rope life and more reliable shovel operation. With shovel downtime estimated at $22,000 per hour and hoist rope sets costing $20,000 to $30,000, the system represents an 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 system was developed following on-site evaluations that identified recurring rope damage at the dipper interface. While some operators previously relied on sheet metal wraps or clamps to protect the rope, WireCo’s factory-installed solution is designed to be faster, safer and more effective.
Now at the patent-published stage in the U.S., WireCo is exploring additional applications for the Gladiator Shield technology in areas of shovels and draglines subject to 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.”
