Hybrid connectivity for mining: keeping OT systems mobile and reliable

Mining is an industry in constant motion — both physically and operationally. As terrain shifts and mine sites expand, maintaining reliable communication networks becomes a major challenge. Traditional networks often struggle to keep up, leading to connectivity gaps that impact safety, productivity and efficiency.

To address this, hybrid connectivity solutions are emerging as the future of mining communications, ensuring that operational technology systems remain seamlessly connected — regardless of location or network conditions.

The critical role of OT in mining

Operational technology (OT) refers to the systems that control and monitor industrial processes, from fleet management and fatigue detection to automation and remote asset monitoring. Unlike traditional IT networks, OT requires low-latency, high-reliability connectivity to ensure real-time decision-making and operational safety.

However, maintaining consistent connectivity for OT systems in mining presents unique challenges:

• Rapidly changing landscapes — Excavation and terrain modifications can disrupt line-of-sight for traditional radio networks.
• Remote locations — Many mine sites are far from established infrastructure, limiting access to fixed connectivity solutions.
• On-the-move operations — Vehicles and equipment constantly shift across large sites, requiring seamless network transitions.
   

Traditional approaches, such as private LTE or radio-based mesh networks, often struggle to provide full coverage across dynamic environments. This is where hybrid connectivity offers a superior solution.

What is hybrid connectivity?

Hybrid connectivity is an approach that combines multiple network technologies — including private LTE, 4G/5G, satellite, microwave and mesh networking — to create a seamless and resilient communications environment. Instead of relying on a single network type, hybrid solutions dynamically switch between available connections based on performance, ensuring continuous uptime and optimal data flow.

This means mining operators benefit from:

• Extended coverage — Connectivity can be expanded into new areas instantly, without waiting for infrastructure upgrades.
• Built-in redundancy — If one network type fails, another automatically takes over, preventing downtime.
• Optimised performance — Critical OT systems are always connected to the lowest-latency option, while non-urgent data is assigned to secondary networks.

Hybrid connectivity in action

Progility Technologies specialises in designing and implementing end-to-end hybrid network solutions that keep mining operations connected. The company has deployed hybrid mobility mesh solutions for some of Australia’s largest mines, using the Rajant Breadcrumb platform as the foundation.

A hybrid solution allows mining vehicles and OT systems to roam seamlessly between network types — ensuring continuous connectivity, no matter the location or terrain conditions. This approach has transformed OT communications by enabling:

• Fatigue detection systems in light vehicles (LVs) to function beyond the mine perimeter, switching securely to public 4G/5G networks when needed.
• Satellite-connected mobile machines to act as network relays, providing temporary coverage in areas with connectivity gaps.
• Flexible, on-demand network expansion, where a temporary satellite node (eg, Starlink) can be deployed to cover a newly developed site.
• Intelligent backhaul prioritisation, ensuring that critical systems always take the fastest, lowest-latency route, while non-essential data defaults to cost-effective alternatives like Starlink.

Why settle for just LTE?

Mining operations demand connectivity solutions as adaptable as the industry itself. Relying solely on LTE limits flexibility and increases the risk of downtime. A hybrid approach delivers a cost-effective, scalable and high-performance solution, ensuring that OT networks remain future-ready.

As the mining industry continues to embrace automation, real-time monitoring and AI-driven operations, hybrid connectivity will be essential for ensuring seamless, secure and resilient communications. For more information on how hybrid connectivity can transform your mining communications, contact Progility Technologies at www.progility.com.au.

Top image: How hybrid connectivity works in a mine site to maximise OT technology reliability.