Vehicle connectivity is now a critical enabler for modern mining operations. From fleet management and safety systems to remote access and cloud-based reporting, connected vehicles are essential to productivity and visibility across site.
However, while many mining organisations focus on the headline price of connectivity hardware, the true cost of vehicle connectivity often runs much deeper — and is frequently underestimated.
Understanding these hidden costs is the first step toward reducing them.
The Visible Cost: Hardware Per Vehicle
The most obvious cost is the price of the connectivity hardware installed in each vehicle.
Traditional vehicle-based RF mesh networks often involve:
- Specialised proprietary radios
- Multiple antennas per vehicle
- Vehicle-specific configurations
In many deployments, this results in per-vehicle costs exceeding $14,000 once hardware and accessories are included.
While this upfront cost is significant, it is often only part of the overall financial impact.
The Hidden Cost of RF Engineering and Commissioning
Mesh networks require careful RF design to function effectively. This often includes:
- Site RF planning and surveys
- Antenna placement optimisation
- Commissioning and tuning
- Reconfiguration as fleets or layouts change
These activities require specialist skills and time, adding both initial deployment costs and ongoing engineering overheads as the operation evolves.
Deployment Time Is a Cost Multiplier
Time spent deploying connectivity is time vehicles are not fully productive.
Traditional connectivity rollouts can take days or weeks, particularly on large or complex sites. Delays during mobilisation, expansion, or temporary works can directly impact operational schedules.
Faster deployment reduces:
- Labour costs
- Downtime during commissioning
- Delays to operational readiness
Connectivity solutions that are quicker to deploy deliver immediate cost benefits.
The Cost of Complexity Over Time
Complex networks become more expensive to operate the longer they are in place.
As mining operations change, connectivity systems often require:
- Retuning when fleets expand or contract
- Troubleshooting intermittent coverage issues
- Specialist support to resolve faults
These ongoing operational costs are rarely captured in the initial business case, but they accumulate over the life of the system.
Fleet Dispersion Drives Up Costs
Modern mining fleets are increasingly dispersed:
- Light vehicles operating kilometres from core plant
- Maintenance crews working independently
- Satellite work areas and temporary zones
Connectivity models that depend on vehicle proximity struggle in these environments, often requiring additional infrastructure, repeaters, or gateways to maintain coverage — all of which add cost.