Author: YZH Publish Time: 2025-09-14 Origin: https://www.yzhbooms.com/
Let me tell you about the installation from hell. Three years ago, copper mine in Chile. Everything that could go wrong, did. Underground water line nobody knew about. Crane got stuck in mud. Concrete pour happened during a surprise rainstorm. What should have been a two-week job stretched to six weeks.
That disaster taught me more about installations than the previous fifty successful ones combined. Here's what really happens when you install a pedestal boom – and how to avoid the disasters I've seen.
Your Drawings Are Probably Wrong
I don't care how good your engineering team is. Something on those drawings doesn't match reality. Maybe the crusher is 18 inches further north than shown. Maybe there's a support beam that's not on the plans. Maybe the floor isn't level.
I always tell clients: budget an extra day for "surprises." Because there will be surprises.
Foundation Work Sucks
Nobody likes talking about foundations because they're boring. But screw up the foundation and your $200,000 boom system becomes a very expensive paperweight.
The hole is massive. We're talking about moving 50+ cubic yards of dirt and rock. In a working mine or quarry. While crushers are running nearby. It's loud, dusty, and miserable work.
And concrete? Concrete has its own agenda. Too hot, it sets too fast. Too cold, it won't set at all. Windy day? The surface dries out and cracks. Rain? Game over.
I've seen concrete pours delayed three times because Mother Nature didn't get the memo.
Days 1-2: The Big Dig
Excavation looks straightforward on paper. In reality, you're working around existing equipment, underground utilities, and whatever else is buried down there.
Last month in Nevada, we hit an old mine shaft nobody knew existed. Added two days to the schedule while we figured out how to work around it.
The rebar cage weighs about 2 tons and looks like modern art. Takes a full day to assemble properly. Rush this and you'll have concrete problems later.
Day 3: Concrete Day
This is the day everyone holds their breath. We need 12 cubic yards of high-strength concrete delivered continuously. No stopping halfway through.
The concrete truck gets stuck? We're screwed. Pump breaks down? We're screwed. Rain starts falling? You guessed it.
I always have backup plans for concrete day. Backup supplier. Backup pump. Weather radar on my phone.
Days 4-7: Hurry Up and Wait
Concrete curing is like watching paint dry, except more expensive. Can't rush it. Can't work around it. Just wait.
This is when we prep everything else. Run electrical conduit. Stage hydraulic components. Double-check crane access. Find all the problems we missed during planning.
Days 8-9: Pedestal Goes In
The pedestal base is a 12-ton chunk of steel that needs to land within 1/4 inch of perfect. No pressure.
Crane work makes everyone nervous. Big crane, heavy load, tight spaces. I've seen experienced operators break out in sweat during these lifts.
Weather matters. Wind over 15 mph and we shut down. Rain makes everything slippery. Hot sun creates thermal updrafts that mess with crane stability.
Days 10-11: Boom Assembly
Each boom section weighs 3-5 tons. Hydraulic cylinders, electrical cables, position sensors – hundreds of components that all need to work together.
This is detail work. Every hydraulic fitting gets torqued to spec. Every electrical connection gets checked twice. Every mechanical joint gets inspected.
Boring? Yes. Critical? Absolutely.
Day 12: Hydraulic Hookup
Hydraulic systems are unforgiving. 3,000 PSI doesn't care about your schedule or budget. Get it wrong and someone gets hurt.
We pressure test everything at 4,500 PSI. Every fitting. Every hose. Every connection. Takes most of the day, but it's worth it.
Found a bad fitting during testing last month. Would have failed catastrophically during operation. Better to find problems on the test bench than in production.
Your crusher control system was designed by one company. The boom control system by another. Getting them to play nice together is like mediating a divorce.
Safety Interlocks
These aren't suggestions. They're requirements. Boom won't operate unless crusher is stopped. Position sensors prevent the boom from hitting the crusher. Emergency stops everywhere.
I've seen operators try to bypass safety systems to "save time." That's how people get killed.
Making It Operator-Friendly
Controls need to be simple enough for a tired operator at 2 AM to use safely. Complicated interfaces lead to mistakes. Mistakes around heavy machinery lead to accidents.
We spend days programming the interface. Testing every button. Every screen. Every alarm. Because the operator's life depends on it working right.
Lockout/Tagout
Hydraulic systems hold pressure even when shut down. Electrical systems can have multiple power sources. Everything needs proper isolation procedures.
I carry scars from a hydraulic line that wasn't properly depressurized. Hydraulic fluid injection injuries are nasty. Don't learn this lesson the hard way.
Fall Protection
Boom maintenance means working at height. Permanent anchor points cost money upfront but save lives later.
Temporary systems are tempting but dangerous. Invest in proper permanent fall protection. Your insurance company will thank you.
Underground Surprises
Always have utilities marked. Always. I've seen power lines, water mains, gas lines, and fiber optic cables that weren't on any drawing.
One job in Australia, we hit an underground fuel tank from the 1960s. Environmental cleanup added $50,000 to the project cost.
Weather
Concrete work stops in rain. Crane work stops in wind. Electrical work stops in lightning. Mother Nature doesn't care about your schedule.
Build weather delays into your timeline. Especially during rainy season.
Access Problems
That crane path you planned? The one that looks perfect on paper? There's probably a utility pole or overhead line you missed.
I always walk the crane path with the operator before the lift. Find problems before the crane shows up.
Hydraulic Testing
We test everything at 150% of operating pressure. Sounds excessive until you've seen a hydraulic line fail during operation.
Takes a full day. Every fitting. Every hose. Every connection. Document everything.
Function Testing
Full range of motion. Load testing with the actual breaker. Safety system verification. Emergency procedures.
This isn't a quick check. We run the system through every possible scenario. Because the first jam clearance isn't the time to discover problems.
Operator Training
Two days minimum. Normal operation, emergency procedures, basic maintenance, troubleshooting.
Good operators make the system work. Bad operators break expensive equipment. Invest in proper training.
First 30 days are critical. This is when you discover what the installation manual didn't tell you.
Daily Inspections
Visual checks every day. Hydraulic leaks, loose connections, unusual noises. Small problems become big problems fast.
Performance Monitoring
Track everything. Cycle times, pressures, temperatures. Deviations from baseline indicate trouble.
Listen to Your Operators
They'll spot problems before your instruments do. Take their feedback seriously.
Properly installed boom clears jams in 8-10 minutes. Runs months between major maintenance. Operators actually want to use it.
Bad installation? Constant breakdowns, safety issues, operators who avoid using it.
Good installations cost money. Proper foundation work, quality electrical installation, experienced installers, comprehensive training.
Cheap installations cost more. Downtime, repairs, safety incidents, operator frustration.
I've seen both. Trust me, pay for quality upfront.
Got questions about your installation? I've made most of the mistakes so you don't have to. Let's talk.
Kevin Chen
Global Sales Manager, YZH Machinery
