Optimizing and scaling networks in mining: A how-to guide

Networks at mining operations are rarely built on a single technology. Most mines use a combination of technologies for both their corporate IT applications, and for their Operational Technologies (OT) including; cellular LTE, Wi-Fi, and wireless mesh. 5G is an emerging technology that is not yet widely adopted, but several mines are actively exploring and testing its potential.

Underground, some mines still use legacy systems like leaky feeder cables for basic voice communication, but modern operations increasingly rely on Wi-Fi and mesh for both communications and positioning. The right mix depends on your site’s layout, your data needs, and how much technical complexity your team can manage. It also depends on what’s fit for purpose, whether you're enabling tele-remote operations, supporting safety systems like collision avoidance, or simply extending coverage to hard-to-reach areas. Each technology has strengths that suit specific tasks.

To plan for your network capacity needs, start by asking what you need your network to do right now, and what you’ll need it to do in the future. Look at your mine plan, plans for automation and other applications, and expected data loads. It’s easier and cheaper to build in extra capacity up front than to retrofit later.

Consider at least the next five years of your mine plan, including how your pits and dumps are going to grow and change. You also should consider what your future automation roadmap looks like.

Most mines currently deploy tele-remote and autonomous machine operation on 4G networks, and if designed correctly and have ample spectrum, they usually don’t have any capacity issues. You need to consider if you really need a technology like 5G, and the technical challenges that come with it. It all comes down to getting the technology tailored to the mine’s operational needs and budget.

Safety solutions like collision avoidance systems (CAS) rely on robust, low-latency networks to function reliably.  As you plan your CAS implementation, make sure your network will be able to support the data and coverage advanced systems require.

Selecting the right network technology mix is also closely tied to your choice of technology. Tag compatibility and network coverage are both critical for effective equipment tracking and the safety of workers.

Site-specific factors include whether your operation is open pit or underground, the size and layout of the site, and the direction of data flow (uplink versus downlink). The key is to match the network design to the realities of your site, using the strengths of each technology where they fit best.

Both open-pit and underground mines need comprehensive network coverage, reliable uplink capacity, and robust equipment. For open pit mines, cellular networks provide large coverage areas but may struggle to reach deep into pits or behind dumps as the mine dynamically evolves, which is a challenge for fixed infrastructure. To fill thesecoverage gaps , miners use portable solutions such as ruggedized, easily movable “cells on wheels” or mesh nodes. 

Underground, you’re covering a small, confined area, which is not typically how we use cellular networks as consumers. It can also be a challenge to protect sensitive cellular network infrastructure from damage. So, Wi-Fi and mesh are often favored underground because they are easier to install in tight spaces and can be quickly replaced if damaged.

Hybrid networks are becoming more common because they let you harness the strengths of both cellular and mesh technologies, making it easier to adapt as your mine grows and changes. This aligns with a lean and practical approach to digital transformation, where flexibility, continuous improvement, and fit-for-purpose solutions are prioritized.

Future-proofing means making smart choices now, so you're not boxed in later. In mining, this sometimes requires balancing the desire for cutting-edge solutions with the realities of maintenance and operational complexity.

The best approach is a pragmatic one: design for your current and near-future needs, use modular and flexible solutions, and make sure your team has the capability to manage the technology you choose. This way, you avoid over-investing in complexity you don’t need, while keeping your options open.

Finally, it is important to keep in mind that technology adoption is only successful when people are on board, and the human side of digital transformation is addressed through effective change management. With a balance of technology and human insight, you can build a connected mine that supports your needs today and your vision for the future.

At Epiroc, we are committed to supporting our customers’ journey toward automation and digitalization. As a leading provider of mining equipment and solutions, we bring the expertise, resources, and innovative technologies needed to implement the most suitable network solutions for each site’s unique requirements.

In recent years, we have expanded our portfolio of digital offerings, including Networks as a Service and advanced network analysis tools. These solutions help ensure secure and reliable data flow as the industry moves toward greater automation and integration.

We work closely with mining companies to support successful digital transformations. Whether it’s assessing your mine site, identifying cost-effective solutions, or integrating new technologies, we’re here to support you.