| Written by Mark Buzinkay
Monitoring movements in mining
Monitoring miners and vehicles in underground and open-pit mines in real time involves integrating several technologies to ensure safety, optimise operations, and improve productivity. In both settings, Real-Time Location Systems (RTLS) play a central role. These systems typically use a combination of technologies such as RFID, Wi-Fi, UWB (Ultra-Wideband), BLE (Bluetooth Low Energy), GPS, and mesh networks to track personnel and equipment with high accuracy. In open-pit mines, GPS is the backbone of tracking because of its wide satellite coverage and unobstructed line-of-sight. Vehicles such as haul trucks, dozers, and drilling rigs are fitted with GPS-enabled telematics systems that transmit their location, speed, fuel usage, and engine status to a central control room. For miners, RFID tags embedded in helmets or ID cards allow for continuous tracking when they pass through checkpoints or remain in proximity to fixed RFID readers.
Underground environments, however, present unique challenges for wireless communication and satellite-based positioning due to limited line-of-sight and signal obstruction by rock. Here, alternative methods such as UWB or Wi-Fi triangulation are used. UWB is particularly effective in tunnels because of its resistance to signal multipath interference. BLE beacons can be installed at key junctions and machinery zones to provide proximity-based localisation. Mesh networks or leaky feeder systems—cable infrastructures that act like distributed antennas—support data transmission in deeper or more isolated parts of the mine. These systems relay location and status data to surface-level control rooms where it is visualised in monitoring dashboards.
For both underground and open-pit operations, integration with mine management software allows supervisors to track personnel movement, ensure compliance with safety zones, automate evacuation procedures, and analyse productivity patterns. In emergencies, the system can be used to quickly locate and communicate with miners or isolate affected areas. Some advanced setups also use AI-based video analytics and wearables equipped with environmental sensors that measure gas levels, temperature, and miner vitals, further enriching the data available for real-time decision-making.
Zone-based RTLS in mines
Zone-based RTLS (Real-Time Location System) is a location-tracking approach that determines the presence of a person or asset within a defined area—or "zone"—rather than providing continuous, pinpoint coordinates. It is widely used in environments where high-precision tracking is either unnecessary or too costly to implement, such as industrial facilities, mines, hospitals, or construction sites.
The core idea behind zone-based RTLS is simple: the environment is divided into discrete zones (e.g., tunnels, loading bays, workshops), and tracking is based on whether a tagged object or person enters or exits one of these predefined zones. These zones are monitored using fixed infrastructure like RFID readers, BLE beacons, Wi-Fi access points, or UWB anchors. The tags worn by personnel or attached to equipment send out signals that are picked up when they come within range of a zone's sensor. The system then logs the time and identity of the tag, effectively stating: "Person A is now in Zone 3."
The granularity depends on the layout and size of the zones and the range of the tracking technology used. For example, passive RFID may work for chokepoint-based detection (e.g., passing through a gate), while BLE beacons can cover broader areas and provide room-level visibility with moderate accuracy. UWB or Wi-Fi triangulation can refine the location estimate, though zone-based systems usually don't require that level of detail.
Zone-based RTLS is especially effective for use cases like mustering (ensuring everyone is accounted for in evacuation zones), access control (restricting personnel to authorised areas - see also: mine site security), workflow tracking (seeing when assets enter or leave a work zone), and safety management (alerting when someone enters a hazardous zone). It is valued for being cost-effective, simple to maintain, and scalable, especially in environments with communication constraints like underground mines.
RFID tag tracking system
In an open-pit mine, a zone-based RTLS using RFID tag tracking is typically implemented to monitor the presence and movement of workers and vehicles across designated operational zones, such as blasting areas, loading bays, maintenance yards, fueling stations, and administrative zones. The system relies on RFID tags assigned to personnel (usually embedded in ID cards, wristbands or safety helmets), vehicles (attached to the cab or chassis), and fixed RFID readers or gateways installed at strategic chokepoints.
When a person or vehicle enters or exits a defined zone, the RFID reader detects the tag within its range and sends the tag's ID, timestamp, and zone ID to a central RTLS server. This doesn't track the exact position in real time across the whole site, but it does log zone-level presence: for example, "Excavator 204 entered the Loading Zone at 09:13" or "Operator John Silva is now in the Blasting Area." Readers are typically installed at access roads, gates, workshops, and other high-traffic or sensitive locations regarding mine security.
The system architecture is straightforward. Passive RFID systems may be used at vehicle access points and personnel gates, since these rely on proximity and don't require batteries. Active RFID tags (battery-powered) are often used for larger coverage zones or moving equipment, emitting a signal that can be picked up from 10–100 meters, depending on the frequency and reader sensitivity. In such cases, readers might be mounted on poles, buildings, or mobile units (e.g., towers on vehicles) to form coverage bubbles.
The primary advantage of this system is operational awareness. Supervisors can check who is in which area, ensure that workers don't enter restricted or unsafe zones, and get a real-time overview of workforce distribution. During emergencies, the system enables rapid headcounts and location-based alerts. It also supports automation, such as preventing vehicle ignition if a tag isn't detected, or logging fuel usage by zone. While it lacks the granularity of GPS-based or UWB-based continuous tracking, it's more cost-effective and robust, especially in dusty, harsh environments where minimal maintenance is crucial.
Key success factors for an RFID tag tracking system
The key success factors for RFID tag tracking systems in open-pit mines revolve around safety, operational efficiency, compliance, and cost control. For mine operators, investing in RFID-based zone tracking brings both tangible and strategic benefits, especially as mines grow in size, complexity, and automation.
1. Improved Safety and Emergency Response
Safety is the most critical concern in open-pit mining. RFID systems provide real-time visibility into the location of personnel and vehicles across zones, helping to enforce safety protocols. For instance, if a blast is scheduled in Zone A, the system can verify that no personnel tags are present before authorisation is given. In the event of an emergency, such as a landslide or chemical spill, the system enables rapid mustering and automated headcounts, speeding up evacuation and rescue operations.
2. Access Control and Zone Restriction
By defining who can enter specific zones, RFID systems reduce the risk of unauthorised or underqualified personnel entering hazardous or restricted areas. For example, only maintenance staff with proper training might be allowed to enter high-voltage zones. This supports regulatory compliance and enhances site discipline without requiring manual checks.
3. Operational Visibility and Workflow Optimisation
Knowing where people and assets are at any given time allows supervisors to monitor shift changes, equipment usage, and idle time. For instance, RFID data reveals inefficiencies if vehicles spend too long in queue zones or if refuelling stations are underused. This can lead to better scheduling, reduced bottlenecks, and improved equipment utilisation.
4. Compliance and Reporting
Mine operators must often prove adherence to safety standards, labour regulations, and environmental policies. RFID systems automatically log access and movements, providing an auditable trail of who was where, and when, reducing paperwork and supporting compliance during inspections or incident investigations.
5. Cost-Effectiveness and Scalability
Compared to more complex tracking technologies like UWB or GPS (which may require line-of-sight and extensive infrastructure), RFID systems are affordable, rugged, and easy to scale. They also have a long lifecycle and can operate in dusty, muddy, or metallic environments typical of open-pit operations.
Case Studies for an RFID tag tracking system
Anglo American – RFID for Personnel Tracking in Chile (El Soldado Mine)
At Anglo American's El Soldado mine in Chile, an RFID-based tracking system was implemented primarily to improve underground and pit safety. The system uses active RFID tags (typically operating at 433 MHz) worn by personnel or mounted on vehicles. Fixed readers installed at zone entry points or tunnel junctions detect these tags, allowing site managers to know who is located where within a large, complex mining site.
The primary motivation for the deployment was collision prevention and emergency response. By knowing the real-time location of workers and heavy vehicles, the system could issue alerts when personnel entered high-risk zones such as haul truck corridors or blasting areas. It also significantly improved the mine's ability to respond during evacuation drills, reducing average mustering time and improving headcount accuracy.
The system reportedly enabled Anglo American to automate access logs, analyse workforce distribution, and reduce downtime during shift changes, contributing to both safety and productivity.
BHP – Vehicle Zone Monitoring and RFID at Pilbara (Australia)
While BHP has not publicly detailed a specific RFID-only implementation, their operations in the Pilbara region of Western Australia have integrated a broad suite of tracking and automation technologies, including RFID in some vehicle access and infrastructure systems.
In BHP's strategic environmental assessments and technology modernisation plans, the company has referenced automated and semi-automated systems for managing fleet movement, restricting access to critical areas, and reducing queuing times in fuel and maintenance zones. RFID plays a role here by identifying vehicles as they approach these service areas, triggering pre-authorised entry, and logging time spent in each service zone.
Even though this may be part of a broader telematics system, RFID is key at access control points, especially when integrated with boom gates, automated fueling stations, or maintenance scheduling systems. By doing so, BHP improves vehicle turnaround times, reduces idling emissions, and ensures that only correctly serviced or authorised vehicles enter designated zones.
Vale – Safety and Efficiency with RFID and Autonomous Systems in Brazil
Vale has embraced RFID within a broader digital transformation strategy that includes autonomous trucks, machine guidance systems, and personnel tracking in both open-pit and underground mines in Brazil. One highlighted application is the Brucutu mine, one of the first to fully implement autonomous truck operations.
In these environments, RFID tracks personnel movements, ensuring no workers are present in areas where autonomous equipment is operating. Tags embedded in PPE or ID badges are picked up by readers placed around autonomous corridors. If a human enters an area restricted for robots, alerts are generated, and operations may halt automatically, creating a safer interaction between manned and unmanned systems.
Additionally, Vale has used RFID tags on equipment and maintenance tools, enabling better inventory tracking and reducing equipment search times. The overall result has been a more than 20% increase in productivity in certain areas and a sharp drop in incidents involving unauthorised zone access.
FAQ
What are the main benefits of using RFID tracking in open-pit mines compared to GPS or more advanced RTLS technologies?
RFID offers a cost-effective, rugged, and reliable solution for zone-based tracking, especially in environments where high-precision, continuous location data isn't essential. Unlike GPS, which can be limited by environmental obstructions or requires expensive hardware for dense deployments, RFID systems excel at entry/exit logging, automated access control, and safety zone enforcement with lower infrastructure costs and simpler maintenance.
How does RFID improve safety for personnel and equipment in open-pit mines?
RFID systems track when personnel or vehicles enter predefined zones, such as blast areas, maintenance bays, or fuel depots. This enables real-time zone visibility, automated headcounts, and the prevention of unauthorised access to hazardous zones. During emergencies, the system allows for fast location checks and can trigger alerts if someone remains in a restricted or dangerous area, significantly improving response time and coordination.
Can RFID tracking integrate with other mining systems like fleet management or access control?
Yes, modern RFID solutions can integrate seamlessly with fleet management systems, access control gates, workforce scheduling tools, and environmental monitoring platforms. This integration enables automated workflows, such as denying vehicle ignition if the correct operator tag isn't detected, logging fueling events by zone, or generating compliance reports for safety inspections.
Takeaway
Open-pit mine operators should invest in an RFID tag tracking system because it directly impacts the bottom line through efficiency gains, enhances workforce safety, and supports compliance and operational accountability. These systems are future-ready, meaning they can integrate with fleet management software, automate alerts, and lay the groundwork for further digital transformation initiatives like autonomous vehicle deployment or AI-based predictive maintenance.
Delve deeper into one of our core topics: Mining security
Glossary
A leaky feeder system is a type of underground communication network that uses coaxial cable designed to "leak" radio signals along its length, functioning like a distributed antenna. It enables continuous voice, data, and tracking communication in tunnels or shafts where traditional radio signals can't propagate. Commonly used in mines, it supports two-way radios, Wi-Fi, and RFID readers. It's scalable, reliable, and critical for safety and real-time operations underground. (4)
References:
(1) "Chilean Copper Mine Tracks Vehicles and Workers," RFID Journal, March 6, 2008. https://www.rfidjournal.com/news/chilean-copper-mine-tracks-vehicles-and-workers/81169/
(2) "BHP Pilbara Strategic Assessment," BHP, September 30, 2024. https://www.bhp.com/-/media/bhp/regulatory-information-media/iron-ore/western-australia-iron-ore/whaleback/western-ridge-draft-validation-notice-appendices/western-ridge-validation-notice-30september2024_optimized.pdf
(3) https://vale.com/w/vale-expands-the-use-of-autonomous-equipment-and-has-72-pieces-operating-in-brazil-benefiting-directly-more-than-300-employees
(4) Sikora, A., & Wrona, K. (2014). Leaky feeder systems in underground mines. Journal of Telecommunications and Information Technology, 2014(1), 76–83.
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