In the world of mining, time is money — and when it comes to installing heavy mechanical equipment, delays can cost millions. Whether it’s crushers, mills, screens, or conveyors, getting mechanical components on-site, installed, aligned, and running safely is a critical milestone in any mining project. But it’s far from simple.
Mining sites across Africa face a unique set of challenges — from remote locations and unpredictable terrain to cross-border logistics and the sheer scale of the equipment involved. In this blog, we break down the biggest challenges and share best practices that leading companies like S.M.E.I. Projects use to keep operations moving forward.
1. Getting the Equipment to Site: Logistics at Scale
Unlike factory installations in urban areas, mining sites are often hundreds of kilometres from the nearest port or warehouse. Just transporting a mill, for example, can take days of coordination and special load permits. In one recent South African case, a 2.5 MW ball mill had to be moved over six days by road, with escort vehicles and route modifications.
Common challenges:
- Overweight and oversized loads
- Border delays for cross-country projects
- Road infrastructure damage or seasonal inaccessibility
Best practice:
Pre-shipment route assessments, local transport partnerships, and modular equipment packaging (splitting larger components into transportable units) can save time and avoid last-minute complications.
2. Working with Limited Infrastructure
Many remote sites lack craneage, power supply, or level foundations — all of which are essential for safe mechanical installations. Contractors must bring in equipment like mobile cranes, jacking systems, or temporary power, and prepare foundations to exact tolerances before machinery even arrives.
Best practice:
Companies like S.M.E.I. Projects conduct detailed site readiness audits. This includes checking whether civils are truly ready — misaligned bases or uneven surfaces can cause dangerous stress on installed equipment.
3. Aligning and Commissioning Equipment Under Pressure
Installing mechanical components isn’t just about placing them — they must be precisely aligned, bolted, grouted, and tested. Even slight misalignments can lead to:
- Premature bearing failure
- High vibration levels
- Inefficient throughput and energy loss
Example:
At a large copper project in the DRC, contractors used laser alignment tools and digital torque monitoring to ensure mills and drives were installed within tolerances of less than 0.1 mm. These precision tools help reduce wear and extend the lifespan of expensive assets.
4. Dealing with Unpredictable Weather and Site Conditions
Weather can delay concrete curing, stop cranes from operating, or make roads impassable. Add in safety concerns — such as working at height, lifting heavy components, or navigating muddy terrain — and it’s clear why experience counts.
Best practice:
Leading contractors build in weather contingency days and prioritise safety briefings and hazard identification before every major lift or alignment task.
5. Planning for Future Maintenance
One of the most overlooked parts of mechanical installation is planning for long-term access and maintenance. Once a plant is operational, the cost of shutting down equipment for maintenance skyrockets.
Smart approach:
Installations are designed with removable panels, access walkways, lifting points, and proper documentation. The S.M.E.I. Project teams often work alongside operations staff to understand future needs and make sure maintenance won’t be a logistical nightmare later.
Final Thoughts
Installing mechanical equipment in mining environments is more than just a technical task — it’s a high-stakes orchestration of people, equipment, safety, logistics, and timing. When it’s done well, production starts on time and runs smoothly. When it’s rushed or mismanaged, the consequences can be severe.
That’s why experience matters. Contractors like S.M.E.I. Projects bring not only the tools and technical skills, but also the on-the-ground know-how to anticipate challenges and deliver installations that perform reliably from day one.
Need expert support for your next mechanical installation? From crushers and mills to conveyors and custom plant layouts, S.M.E.I. Projects delivers precision installations built to perform in Africa’s toughest conditions.