How Drones in Mining Boosts Efficiency

Before the early 2010s, mining operations in Australia were becoming increasingly inefficient. As ore grades declined, mining companies found it harder to reach deposits.

Workers had to operate in dangerous environments to check high-wall stability, stockpile volumes and blast areas. With deeper pits being created, energy consumption increased, seeing operational costs soar and reducing overall efficiency.

Worker health and safety remained the main goal across Australian mining sites. Workers dealt with machinery, gases, dusts, chemicals and extreme temperatures. The confined spaces of underground operations also put workers at extra risk.

They often struggled with stress-related illnesses, which were exacerbated by the long-distance commutes. This all changed with the adoption of drone technology.

The Rise of the Mining Drone

The mining industry’s adoption of drones was steady at first, but today, around 70% of large mining companies use unmanned aerial systems. These companies initially used drones for surveying and mapping, but their applications have expanded over time.

To integrate drones into their operations, mining companies have had to navigate and, in some cases, establish regulatory frameworks to ensure safe and compliant usage. The adoption of drones in mining is subject to regulations that vary across regions and countries.

In Australia, the Civil Aviation Safety Authority (CASA) enforces strict safety assessments to ensure that drone operations meet safety standards. This regulatory support has been crucial in facilitating the adoption of drones within the mining sector. To get a Remote Pilot Licence (RePL) in Australia, drone pilots must complete training that meets CASA standards. Once these frameworks had been established and the remote pilot licences acquired, drone operations began.

The large amounts of data that drones collect are used to create detailed 3D models, digital elevation maps and orthophoto maps that help make precise decisions in mining operations. As a result, new roles and teams were created in the industry, in areas such as:

• Data management and processing
• Regulatory compliance monitoring
• Equipment maintenance and calibration

Over time, drone technology grew beyond simple surveying. Today’s drones perform autonomous mine inspections, manage stockpiles, monitor drilling operations and assess environmental conditions. The blend of AI with drone systems has increased efficiency, especially when you have predictive maintenance and risk assessment needs.

Integration Challenges and Solutions

Mining drones offer clear benefits, but implementing them presents specific operational challenges. Mining companies must overcome several hurdles that require well-defined solutions to adopt them successfully.

Data Management Systems Setup

Mining drones generate massive amounts of data. A single drone flight can capture over 6,000 high-resolution images that teams must convert into orthomosaic images and 3D models. As a result, a resilient management system and processing protocols are required.

Mining companies now use cloud-based processing solutions that require just 1GB of RAM to handle 400 images from standard mining drones. This solution handles data quickly while keeping it accessible across multiple mine sites.

Regulatory Compliance Framework

Mining companies must meet strict regulatory requirements before they can start drone operations. Australian operators need remote pilot licences for commercial drones weighing over 2kg, and the CASA requires registration of all commercial drones.

Drone use in mining often extends beyond standard operations. For example, flights above 400 feet over pit floors require special area approvals. Operators must also obtain specific authorisations to fly over company personnel and equipment.

Team Adoption Strategy

The success of mining drones depends on how well teams adopt them. Mining drone pilots need advanced permissions that go beyond their commercial permits. As a result, mining companies must invest in specialised training programs to ensure their drone operators are fully equipped to handle complex flight operations and regulatory requirements.

Structured training and clearly defined protocols are key to delivering consistent results. BHP, for example, has a team of over 50 drone pilots that run about 600 flights across six mine sites per month.

Types of Drones and their Applications

Australian mining operations use specialised drones to match their specific operational needs. Unmanned aerial vehicle (UAV) systems are classified into four main categories by weight: 

1. Micro (up to 250g)
2. Very Small (250g to 2kg)
3. Small (2-25kg)
4. Medium (25kg – 150kg

Fixed-wing drones excel at surveying large mining sites. They can fly for up to 90 minutes at speeds of 110km/h and are great for large-scale mapping projects. However, their landing requirements create challenges in rough terrain.

Vertical take-off and landing (VTOL) systems have become the preferred choice in mining. They combine fixed-wing endurance with multirotor manoeuvrability. The WingtraOne GEN II, built specifically for mining, can fly for 60 minutes and cover almost 300 acres in one mission.

Underground operations require specially designed collision-tolerant drones with 10,000-lumen dust-proof lighting systems. These drones use sophisticated sensors to navigate in tight spaces without GPS.

Each drone type serves a specific purpose in mining operations:

• Mapping and Exploration: Fixed-wing and VTOL platforms use magnetometers and LiDAR sensors to detect minerals and create geological maps. These systems find ore bodies by detecting variations in magnetic fields.
• Stockpile Management: Multirotor drones with photogrammetry sensors measure volumes with accuracy within 1% of traditional methods.
• Safety Inspections: Collision-tolerant drones use thermal cameras to check equipment and monitor unstable slopes while keeping personnel safe.

The (Undeniable) Benefits

The numbers prove that UAVs provide significant advantages in many areas.

Reduction in Survey Time

Drones have revolutionised traditional surveying speeds, completing operations 30 times faster than ground teams. Tasks that used to take two months now take just a few hours. For example, a team of four drone pilots mapped an entire 13.7km² Australian limestone quarry in just one day.

Cost Savings

Drones save money through remote equipment checks. Unplanned equipment downtime in the mining industry can lead to significant financial losses. Estimates suggest that downtime costs can range from $1,000 per hour for certain equipment, such as mining dump trucks or excavators, to as high as $100,000 per hour for critical machinery like baghouse fans and mills

Enhanced Safety

Safety improvements stand out as a key benefit. Drones keep workers away from dangerous areas, especially during:

• Measurements of stockpiles with unstable slopes
• Checks of underground spaces after blasts
• Inspections of high-walls and crests in open-pit mines

Additional Benefits

Drones offer many more advantages beyond the basics:

• They measure volumes with 1% accuracy compared to standard methods and can survey an entire ROM pad in just 30 minutes.
• Underground mining uses special crash-resistant drones to create detailed maps with more than 100 points per square metre.
• Drones with gas sensors help track methane, sulphur dioxide, and other air pollutants. As a result, mining companies can comply with environmental rules without slowing down their work.
• Mining companies that use drones cut their aerial survey costs by up to 90%. Better data accuracy and worker safety make drones a game-changer in modern mining.

Real Applications of Mining Drones  in Australia

Australian mining operations have shown remarkable success with drone technology. 

BHP

BHP’s Olympic Dam mine in South Australia spans an impressive 180km² and uses fixed-wing drones for beyond visual line of sight (BVLOS) operations. These drones captured over 8,000 high-resolution images with 7cm per pixel accuracy, covering roughly 1,200km in just 12 hours.

Meanwhile, BHP’s iron ore operations in Western Australia maintain a skilled fleet of active pilots. Each pilot is CASA-certified to ensure they meet all regulatory standards.

BHP’s Carrapateena mine, one of Australia’s biggest copper reserves, puts autonomous drones to work for crucial underground monitoring. These specialised units can direct themselves without GPS signals and descend 70 metres into mega-caves to gather vital data without putting staff at risk.

Jellinbah

Queensland’s Bowen Basin is home to the Jellinbah coal mine, which has partnered with Dendra to showcase innovative environmental applications. Their drones help track rehabilitation efforts and precisely monitor vegetation growth and erosion patterns. The technology has helped identify problem areas that need attention, leading to successful rehabilitation results.

Glencore Australia

Glencore Australia runs an impressive drone programme that spans 34 mine sites in four states. Their system directs over 300 pilots who work in coal, copper, zinc, nickel, and agricultural operations. Using standardised procedures and Flyfreely’s offline-capable field applications, Glencore has reduced site deployment time from several months to just two hours.

Commonwealth Scientific and Industrial Research Organisation (CSIRO)

CSIRO’s research shows that drone-based mineral exploration in remote Australian regions has become quicker and more efficient. Their studies reveal that mobile applications combined with drone technology streamline data collection. This is huge, as it means that helicopter-based survey costs have dropped by about 40-50%.

Growing Demand for Drone Pilots in Australia

Drone technology’s rapid adoption in Australian mining has created a huge demand for skilled pilots. Depending on their experience, drone pilots working in Western Australia’s mining, oil and gas sector can earn between $150,000 and $200,000 per year.

Employers look for candidates skilled in:

• Data processing and analysis
• Geospatial mapping
• Advanced flight planning
• Risk assessment
• Emergency response protocols

Mining companies need pilots who can handle different types of drones, from automated systems to manual remote-controlled units. The global mining drone market will grow at 20.4% annually through to 2030, which shows excellent career opportunities in this field.

You will of course need a Remote Pilot Licence (RePL) to operate drones above 2kg commercially for entry-level positions. Advanced roles require extra certifications that focus on BVLOS operations and complex flight scenarios.

Interested in Becoming a UAV Pilot for the Mining Industry?

At Toll Uncrewed Systems, we offer comprehensive in-person Brisbane RePL courses with world-class instructors right there in the classroom with you—no video calls, just face-to-face learning.

Our teaching style is hands-on and direct. We monitor your progress closely and stay with you until you secure your licence.

Get in touch with the team today and together we’ll take your career to new heights.