Industries

Headframe is a hoisting tower that connects the underground mine with the surface. Installed directly above the shaft, it supports the lifting and lowering of ore, personnel, and materials, as well as ventilation and drainage systems. When transporting personnel, a cage attached to the end of a wire rope is moved up and down using a winch.

When suspending large equipment into the shaft or replacing the cage elevator, the cage is detached from the wire rope and connected to an ER2M electric chain hoist. Equipped with highly reliable electromagnetic brakes, overload protection, and other safety features, as well as a nickel-plated chain resistant to rust and corrosion, ER2M enables safe and efficient replacement operations.

The fourth and fifth attached photos show large equipment being lowered into the shaft using Crosby G-2130 / S-2130 Bolt Type Anchor Shackles. These shackles are fully zinc-coated and have passed fatigue tests of 20,000 cycles at 1.5 times the rated load. Even in the humid and corrosion-prone environment of underground mining, they securely hold equipment in place.

Products Used:

Kito ER2 Electric Chain Hoists

Crosby G-2130 / S-2130 Bolt Type Anchor Shackles

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During the replacement of the hoisting rope, the new rope is connected to the old one and pulled into the hoist room over the sheave of the headframe using a winch. For this operation, Crosby G-450 Clips are used to securely fasten the ropes together, offering performance that exceeds ASME standards.

On the shaft cover, Crosby G-209 / S-209 Screw Pin Anchor Shackles and Crosby Standard Wire Rope Thimbles are used. The shackles feature screw-type pins for easy attachment and removal, and they provide high proof load and minimum breaking strength. Both the shackles and thimbles are zinc-coated, ensuring safe use even in high-humidity environments.

Products Used:

Crosby G-450 Clips

Crosby G-209 / S-209 Screw Pin Anchor Shackles

Crosby Standard Wire Rope Thimbles

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In underground mining, a reliable power network is essential to operate excavation machines, conveyors, ventilation fans, lighting, and communication equipment. Key infrastructure components such as transformers play a critical role in this process. The deeper the mining site, the more susceptible these systems become to voltage drops and transmission losses, increasing the risk of equipment failure.

Because underground spaces are confined and access is limited, repairing or replacing such equipment requires significant time and cost, and downtime caused by failures has a direct impact on productivity. This makes swift and safe maintenance essential.

CB chain hoists and LB lever hoists, along with Crosby shackles, enable safe and secure lifting of equipment even in narrow mine passages, supporting efficient on-site maintenance and replacement work. The CB’s brake cover prevents dust and other contaminants from entering the hoist, while the LB’s nickel-plated chain offers excellent corrosion resistance and performs reliably in high-temperature, high-humidity environments. In addition, the LB’s unique freewheel mechanism allows the chain length to be adjusted quickly and safely, improving productivity in maintenance operations.

Products Used:

Kito CB Manual Chain Hoists

Kito LB Lever Hoists

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Coal offers major advantages as a power generation fuel—it is inexpensive and can be mined in many regions around the world.

However, coal seams are more fragile than those in other types of mines, resulting in a higher risk of roof collapse. In addition, methane gas accumulated in the mine, combined with coal dust, can significantly increase the risk of explosions. Maintaining and expanding mine tunnels safely requires roof support with steel and timber, but steel materials are heavy and difficult to transport manually.

By using “RER2 Hazloc Electric Hoists,” these materials can be transported safely and efficiently. The body minimizes the risk of ignition from electrical sparks, while rubber tires on the trolley allow for rapid travel along inclined underground tunnels. This contributes to building a mining site that combines both safety and high productivity.

Products Used:

Harrington RNER2 Hazloc Electric Hoists

A scraper is a device used in underground mining to collect ore and waste rock from the excavation face and drag it through the tunnel for removal. The ore is gathered using a bucket (scraper blade) attached to wire ropes, and transported to the loading area by pulling it with a winch. Typically, two wire ropes are used to move the winch back and forth, operating the scraper to accumulate the ore.

Crosby G-209 / S-209 Screw Pin Anchor Shackles are used to directly secure the bucket and pull it with the wire ropes. The screw-type pin allows for easy attachment and removal of the shackle, while providing high proof load and minimum breaking strength. This ensures safe and efficient support for the scraper operation, even under intense winch movement.

Products Used:

Crosby G-209 / S-209 Screw Pin Anchor Shackles

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Salt is used in many areas of daily life, including food, agricultural fertilizers, chemical raw materials, pharmaceuticals, water treatment, and de-icing agents. In certain regions of Germany, ancient crustal movements have made it possible to mine salt on land. At one major salt mine, more than one million tons are extracted annually from depths of 500 to 1,000 meters.

To ensure smooth transportation to the surface, excess salt and backfill materials (*) are temporarily stored in underground storage bunkers.

During the construction of one such bunker, ER2 electric chain hoists played a vital role in safely and precisely lowering heavy equipment and materials to the site. In harsh conditions—over 35°C temperatures and salt-laden air—two ER2 units, with rated loads of 5 tons and 7.5 tons, equipped with a corrosion-resistant aluminum die-cast body and nickel-plated load chain, were installed on curved and straight crane tracks along the access tunnel. These hoists ensured the safe and efficient completion of the underground bunker construction.

(*) Materials used to stabilize ground weakened by excavation, such as soil or cement generated on-site.

Products Used:

Kito ER2 Electric Chain Hoists

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A Rope Shovel is a large electric excavator used in open-pit mining to dig and load ore and rock. Compared to hydraulic shovels, it offers greater digging power and is well-suited for excavating hard rock and continuous long-hour operations.

The bucket is operated using wire ropes and can scoop up to 150 tons of rock in a single pass, loading it into massive dump trucks.

Crosby Standard Wire Rope Thimbles are used at the looped sections of the wire rope to prevent wear and distribute load evenly. With hot-dip galvanization, they offer excellent corrosion resistance even in outdoor environments.

The wire rope is connected to the Rope Shovel body via Crosby G-2130 Bolt Type Shackles. These shackles have passed rigorous fatigue and Charpy impact tests and feature high corrosion resistance due to galvanization. They ensure safe and reliable operation even under harsh open-pit conditions, supporting the long-term operation of Rope Shovels.

Products Used:

Crosby G-2130 / S-2130 Bolt Type Anchor Shackles

Crosby Standard Wire Rope Thimbles

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A Dragline Excavator is a large machine that uses a long boom (arm) and a massive bucket suspended by wire ropes to excavate by dragging the bucket toward itself. It is primarily used in open-pit coal and metal mines for removing overburden. With a wider excavation range than a Rope Shovel, it can handle significantly larger volumes of earth in a single operation.

Due to its enormous size, relocating the machine after installation is difficult, so maintenance is typically performed within the open pit. Kito Crosby’s extensive product lineup supports safe and efficient maintenance operations.

During Caterpillar track replacement, Crosby 2130 Bolt Type Shackles and Chain Slings are used for removing and installing the tracks. For tension adjustment and securing during assembly, Turnbuckle HG-226 Eye & Eye and L-140 Standard Ratchet Type Load Binders are employed. These shackles and turnbuckles are hot-dip galvanized and have passed rigorous fatigue testing. The Load Binder features a continuous draw mechanism, allowing precise tension adjustment, making it ideal for this application.

For securing wire ropes, Crosby G-450 Clips are used, offering performance that exceeds ASME standards and excellent corrosion resistance for reliable holding. Boom and sheave replacements involve 85-ton class shackles and chain slings. G-2140 Alloy Bolt Type Anchor Shackles, made from special alloy steel, provide Grade 8 strength—30–40% higher than standard Grade 6 shackles. Gunnebo Industries’ GrabiQ Chain Sling allows quick chain length adjustments with fewer components.

For replacing large engine parts, gearboxes, and switchgear, chain hoists and lever hoists are essential. CB chain hoists feature a unique braking mechanism for high safety and mechanical efficiency. LB lever hoists, equipped with nickel-plated chains for wear and corrosion resistance, offer a lightweight and compact design for easy and safe chain length adjustment—ensuring both safety and efficiency in maintaining ultra-large equipment.

Products Used:

Crosby HG-226 Eye & Eye

Crosby L-140 Standard Ratchet Type Load Binders

Crosby G-2130 / S-2130 Bolt Type Anchor Shackles

Crosby G-450 Clips

Crosby G-2140 Alloy Bolt Type Anchor Shackles

Gunnebo Industries Master Grab Duo MGD

Kito CB Manual Chain Hoists

Kito LB Lever Hoists

Conveyor pulleys (drums) serve as the driving component that transmits motor power to the belt. They are also used at the return end of the belt to reverse its direction or adjust the wrap angle. Neglecting proper maintenance can lead to slippage on the drive pulley, causing the belt to idle. Additionally, ore or mud adhering to the pulley surface can create unevenness, resulting in belt wear, misalignment, or deviation.

Kito Crosby provides a wide range of peripheral equipment necessary for maintenance. Sling chains are used for directly lifting heavy pulleys, and lifting beams can be supplied to match pulley sizes. Crosby G-2140 Alloy Bolt Type Anchor Shackles, featuring a large bow diameter, are ideal for securing high-capacity sling chains. Their Grade 8 body, made from special alloy steel and combined with zinc plating, offers excellent fatigue strength and corrosion resistance—perfect for harsh mining environments.

LB Lever Hoists feature a compact, lightweight body that enables smooth operation even in confined mining spaces, while delivering durability that surpasses competitors. They are also ideal for fine positional adjustments of pulleys and beams, earning high praise from customers who prioritize safety and efficiency.

Products Used:

Crosby G-2140 Alloy Bolt Type Anchor Shackles

Kito LB Lever Hoists

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Mining conveyors, which can extend for tens of kilometers to continuously transport large volumes of ore and rock, place significant loads on the belt. Therefore, it is essential to maintain proper tension to prevent belt wear, elongation, damage, slippage, and misalignment.

Crosby McKissick Snatch Block with Shackle Fitting features a lightweight alloy body, making it easier to handle compared to other products, and allows for simple wire rope installation. By distributing the tension applied to the rope, it ensures proper pulling of the belt.

Additionally, Crosby Straightpoint Wirelink Plus offers IP68 dustproof and waterproof protection along with an aircraft-grade aluminum body, enabling safe use even in harsh excavation environments. When combined with Crosby shackles, it provides real-time monitoring of belt tension, supporting stable conveyor operation.

Products Used:

Crosby McKissick Snatch Block with Shackle Fitting, Single Sheave, 15-60t

Crosby Straightpoint Radiolink Plus (RLP)

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A Gyratory Crusher is a crushing machine that uses a gyrating motion to break down large volumes of rock at once. It is employed in the primary crushing stage of large-scale mining operations and is ideal for processing hard rock such as iron ore and copper ore.

When rocks are fed from above into the bowl-shaped chamber, the central conical Crusher Cone moves in a circular, gyrating motion, continuously compressing and crushing the material. The crushed rock then exits through the bottom of the chamber.

The Gyratory Crusher itself is enormous—smaller units weigh several tens of tons, while larger models can exceed 1,000 tons. As a result, installation requires the use of mobile cranes and the assembly of multiple components. Crosby G-2140 Alloy Bolt Type Anchor Shackles support working loads up to 400 tons. Their zinc-coated bodies provide excellent corrosion resistance, ensuring safe and secure handling of crusher components during crane operations.

For relatively smaller components, G-209 / S-209 Screw Pin Anchor Shackles are ideal, with a working load limit of up to 55 tons. The screw-pin design allows easy attachment and removal of wire ropes or chain slings. Additionally, the Maximum Proof Load is twice the working load limit, and the minimum breaking strength is six times higher, offering exceptional safety.

Standard Wire Rope Thimbles protect wire rope loops from wear and help distribute loads evenly. With hot-dip galvanization, they deliver superior corrosion resistance even in outdoor environments, supporting safe and reliable installation work.

Products Used:

Crosby G-2140 Alloy Bolt Type Anchor Shackles

Crosby G-209 / S-209 Screw Pin Anchor Shackles

Crosby Standard Wire Rope Thimbles

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Parts used in open-pit mining equipment are extremely heavy—the bucket of a hydraulic shovel alone weighs more than 10 tons. These parts often become covered with debris or rust during use, and when lifted by a crane for maintenance, other components can easily get caught.

In such situations, Kito Crosby products help detect overloads and enable safe, efficient maintenance.

Radiolink plus offers a lineup with capacities up to 300 tons and features IP67 environmental protection. Using a dedicated app, real-time load monitoring is possible from up to 100 meters away—or up to 1,000 meters when using the Handheld Plus.

Combined with G-2140 Alloy Bolt Type Anchor Shackles, made from special Grade 8 alloy steel, loads can be lifted safely.

Gunnebo Industries’ GrabiQ Chain Sling is used to lift buckets directly. It allows easy chain length adjustment and, compared to other products, requires significantly fewer components, ensuring highly efficient operations.

Products Used:

Crosby Straightpoint Radiolink Plus (RLP)

Crosby G-2130 / S-2130 Bolt Type Anchor Shackles

Gunnebo Industries Master Grab Duo MGD

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Large bulldozers play a vital role in excavation sites, pushing rocks and ore, leveling ground, and building haul roads. Because they constantly operate on rocky, sandy, and muddy terrain in mining environments, regular maintenance of the tracks is essential.

The key tools for track maintenance are LB Lever Hoist and Crosby HR-125 UNC Threads. Tracks are composed of dozens of links, connected at both ends by a Master Link to form a loop. During maintenance, this Master Link must be removed and reconnected, but the tracks are extremely heavy and cannot be handled while under tension.

To address this, HR-125 UNC Threads are bolted directly into the truck frame to create a strong attachment point. Its 360° rotation and 180° swivel mechanism allow for pulling loads from any direction, while Grade 8 strength and a high safety factor ensure secure operations.

When LB Lever Hoist is connected to this attachment point, its compact yet robust gear mechanism delivers precise tension control, surpassing competing products in accuracy and feel. By properly adjusting tension, these two products enable track maintenance to be performed with outstanding efficiency while maintaining the highest level of safety.

Products Used:

Kito LB Lever Hoists

Crosby HR-125 UNC Threads

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Truck Shop serves as an intermediate point connected to the mining site, where large and long equipment is also brought in.

In these situations, Crosby McKissick Snatch Block plays a key role. In the example shown, multiple Snatch Blocks are installed beneath four Spreader Beams to distribute the load, reducing stress on lifting gear and cranes caused by uneven loads and making it easier to balance the cargo. Its opening mechanism allows wire ropes to be threaded easily, and compared to non-alloy blocks, it is significantly lighter, making on-site adjustments simple.

To secure the ends of wire ropes, Crosby G-209 / S-209 Screw Pin Anchor Shackles are used. Their screw-pin design enables quick rope removal, combining safety and efficiency in field operations.

When mobile cranes are used on-site to lift massive loads, blind spots can occur during lifting, lowering, moving, or slewing operations, creating a serious risk of accidents. In fact, the most common fatal crane accidents are caused by falling objects striking workers or passersby.

BlokCam and BlokAlert help prevent many of these potential accidents through integrated video and audio systems. Thanks to their magnetic mounting, they can be easily attached to hook blocks or buckets below the hook. Operators can monitor loads and surroundings in real time, and if a hazardous situation arises, the audio alert system immediately warns nearby workers to prevent accidents.
Additionally, with IP67-rated dust and water protection, these systems can be used confidently even in harsh mining environments, and they support up to 30 days of loop recording.

Products Used:

Crosby McKissick Snatch Block, Tail Board, Single Sheave, 15-60t

Crosby G-209 / S-209 Screw Pin Anchor Shackles

Crosby G-2130 / S-2130 Bolt Type Anchor Shackles

Crosby BlokCam BlokCam X3L Camera System

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During the process of separating and concentrating valuable minerals from ore in a beneficiation plant, a large amount of water is used. After use, this water contains many mineral particles and chemicals, making it unsuitable for direct discharge.

To meet national and regional discharge standards, the water must be treated using purification equipment.

ER2 electric chain hoist plays a key role in these water treatment facilities. In Papua New Guinea, two ER2 units (3-ton capacity) are mounted on a monorail and are used to regularly lift multiple water purification pumps located in remote areas for maintenance.

ER2 is equipped with IP55 dust- and water-resistant protection, a nickel-plated chain resistant to rust and wear, and a powerful electromagnetic brake, enabling safe and reliable lifting of pumps even under harsh environmental conditions.

Products Used:

Kito ER2 Electric Chain Hoists

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In mining operations, large volumes of water used in facilities such as beneficiation plants are desalinated from seawater for environmental protection and transported through long-distance pipelines. At mines in Chile, pipelines are installed above ground to avoid obstructing the movement of residents and livestock, and Crosby G-450 Clips are used to secure the guy wires that support these pipelines.

These clips meet all ASME standards for ductility, safety factors, and load testing. They are fully coated with hot-dip galvanization, providing excellent corrosion resistance and making them ideal for outdoor applications such as pipelines.

Products Used:

Crosby G-450 Clips

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The tension of guy wires is measured using Crosby Straightpoint Running Line Dynamometer (RLTM). Built with marine-grade stainless steel, the RLTM offers IP67 dust and water resistance and can measure a wide range of wire ropes with capacities up to 150 tons.

The long-range 2.4GHz model enables real-time tension monitoring from distances of up to 700 meters, while the Bluetooth model allows monitoring from up to 100 meters via a smartphone app. This ensures high safety and efficiency during water pipeline construction and maintenance operations.

Products Used:

Crosby Straightpoint Running Line Dynamometer (RLTM)

Project Gallery:

Copper is a metal used in a wide range of applications, including electrical wires, cables, motor coils, printed circuit boards for electronic devices, semiconductor terminals, plumbing systems, and copper tubes for heat exchangers.

In ore, copper exists in the form of compounds called sulfide ores, which cannot be used as-is. To extract metallic copper, smelters employ chemical reactions.

Sulfur is removed from the sulfide ore, and the material is melted at temperatures above 1,200 °C to produce blister copper with a purity of over 99% (almost pure copper). This molten copper is then poured into molds to create metal plates known as Copper Anodes. During this process, Kito Crosby’s lifting equipment is used to transport the molds safely and efficiently.

Crosby Grade 100 A-1343 Welded Master Link is attached to the hook of the crane hoist that moves the molds. Made from specially heat-treated alloy steel, this link meets a 5:1 safety factor and ensures secure handling of the molds.

A-1337 LOK-A-LOY® 10 Alloy Connecting Link features a tool-free locking mechanism, allowing quick and easy attachment or removal. This link connects the master link directly to the mold. In addition, Peerless Grade 100 Alloy Chain is designed for use in high-temperature environments, making it ideal for mold transportation.

Products Used:

Crosby Grade 100 A-1343 Welded Master Link

Crosby A-1337 LOK-A-LOY® 10 Alloy Connecting Link

Peerless Grade 100 Alloy Chain

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In Marine Mining, the self-propelled mining machine known as the “Crawler” operates much like a tracked vehicle on land, moving across the seabed while extracting minerals. The mined ore is pumped up to the vessel through a “Riser Pipe”. Since a Crawler typically weighs several tens of tons, both its installation on the seabed and its lifting back onto the vessel after operations require extremely careful handling.

Supporting these transportation tasks are Kito Crosby’s high-performance lifting solutions. Crosby A-1337 LOK-A-LOY® 10 Alloy Connecting Link is ideal for G80 and G100 chains, ensuring secure attachment of the Crawler. Its locking mechanism requires no special tools, allowing for easy assembly and disassembly.

Additionally, G-209 / S-209 Screw Pin Anchor Shackles enable quick installation and removal by simply screwing the threaded pin into the bow body. G-2130 / S-2130 Bolt Type Anchor Shackles, with their hot-dip galvanized coating, offer exceptional corrosion resistance, and the G-2130OC variant is specifically designed for marine environments.

HR-1200M Metric Side Pull Hoist Rings provide reliable lifting points for these shackles, featuring yellow chromate treatment for enhanced rust resistance, making them ideal for harsh marine conditions. Furthermore, G-416 / S-416 Open Spelter Sockets securely fasten wire ropes, delivering robust support for both seabed installation and lifting operations of the Crawler.

Products Used:

Crosby G-209 / S-209 Screw Pin Anchor Shackles

Crosby A-1337 LOK-A-LOY® 10 Alloy Connecting Link

Crosby HR-1200M Metric Side Pull Hoists Rings

Crosby G-2130 / S-2130 Bolt Type Anchor Shackles

Crosby G-416 / S-416 Open Spelter Sockets

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