NETWORKS & COMMS
Maestro continues Plexus PowerNet™ evolution for last mile connectivity
Back in 2017, Maestro Digital Mine launched the Plexus PowerNet™ which at the time was the world’ s first coaxial-based gigabit network designed to deliver both high-speed data and Power over Ethernet( PoE +) through a single copper coaxial cable for the‘ last mile’ of underground mines. IM spoke to the company for an update on the technology and its progress.
Q Does Plexus PowerNet retain an important niche in underground networks, particularly because of its lower cost and installation complexity?
Yes, Plexus occupies a defined and important role in underground network architecture: extending the established mine network into active headings and all the way to the face. Even when a mine has a fibre backbone, Wi-Fi or private LTE / 5G, it must still bring connectivity- and often power- to the areas where production is actually taking place. These areas are continually advancing, exposed to mobile equipment, blasting, dust and moisture, and subject to frequent changes in layout. Infrastructure that works well in permanent areas may be more difficult or costly to extend and maintain under these conditions. Plexus carries gigabit data and DC power over a single rugged coaxial cable. Each node provides PoE + connections for wireless access points, cameras, environmental monitoring instruments, tracking infrastructure and other IP-based devices. The network can be installed, extended and repaired by trained mine personnel using straightforward tools, without requiring specialised fibre-splicing equipment or a controlled termination environment. This reduces the need for separate power and data cable runs, outside specialists and lengthy restoration work following cable damage. It also allows connectivity to advance at the same pace as development rather than arriving after production has moved elsewhere. Plexus is therefore not positioned as a replacement for every other underground network technology. It complements permanent fibre and wireless infrastructure by addressing the moving last mile- the section of the network that must be repeatedly advanced, reconfigured and maintained close to the work. That combination of performance, durability and maintainability gives it a strong economic and operational role, even as mines adopt more sophisticated communications technologies.
Q Are LTE and 5G networks mainly being used underground where some level of full autonomy is required?
No- autonomy and teleremote operation can provide a strong business case for private LTE or 5G, but they are not the only applications. These networks can also support voice and video communications, personnel and equipment tracking, telemetry, remote technical support and other mobile applications. The economic case becomes stronger when a mine has multiple applications requiring broad coverage, mobility, high capacity and predictable network performance. However, not every application or part of a mine requires that level of wireless infrastructure. Many operations therefore use a hybrid architecture, selecting the most appropriate technology for each area and application. Plexus fits naturally into that approach. It can transport data and power to fixed IP devices or wireless access points without requiring the mine to extend more complex infrastructure all the way to every advancing workplace.
Maestro Digital Mine’ s Plexus PowerNet system is a last mile gigabit network that sends high-speed data and electrical power through a single copper coaxial cable
Q Has Plexus been more successful in particular mine or commodity types or geographical regions?
It is quite a mix. Plexus has been deployed in Canadian gold and base-metal operations, at polymetallic mines in Spain and in African mining operations. Published examples include Newmont’ s Borden gold mine, Vale’ s Sudbury operations, Sibanye-Stillwater and MATSA’ s underground copper, zinc and lead mines. The strongest predictor of fit is not necessarily the commodity. It is the operating environment: mines with advancing work areas, challenging fibre deployment, high equipment traffic, limited access to power or a need to connect and power devices close to the face receive the greatest benefit.
Q Is Plexus particularly useful during mine development or contractor-led phases?
Yes. Mine development is one of the clearest applications because communications infrastructure must continually advance while the mine is still being established. Borden provides a strong example. Plexus was originally deployed during ramp development to support Sandvik AutoMine remote operations. As the mine moved into production, the system was retained and repurposed as the last-mile network from the electrical substations to the active headings. That demonstrates an important advantage: Plexus can meet an immediate development need without necessarily becoming temporary or disposable infrastructure. It can continue serving the operation as the permanent network architecture develops around it. The system may also be useful during contractor-led work because trained development personnel, rather than outside specialists, can install, advance and repair it. It allows useful communications infrastructure to be deployed without waiting for the complete permanent network to reach every workplace.
Q How does today’ s Plexus PowerNet differ from when it was first launched? Has it been refined, and what is the next phase of its development?
Since its launch, the evolution of Plexus has been less about changing its fundamental architecture and more about expanding its capabilities, applications and role within the connected mine. The core principle remains the same: delivering highspeed data and power over one rugged coaxial cable to areas where conventional infrastructure can be difficult to advance and maintain. Today, Plexus provides a fully managed network with diagnostics, SNMP, VLANs, Quality of Service and secure administration. Its application has also expanded beyond connecting wireless access points and cameras. It can support environmental monitoring, equipment telemetry, tracking systems, VoIP, operational displays and ventilation-control equipment. The next phase is tighter integration between connectivity, monitoring, control and analytics. Plexus is increasingly becoming the infrastructure layer that connects and powers Maestro devices throughout the working areas, including our Vigilante AQS V2 air quality monitoring stations, automated regulators and PoEenabled SuperBrite Marquee digital signage displays. Combined with centralised diagnostics and analytics through our new Duetto Analytics platform, this will give mines greater visibility into both their underground conditions and the health of the connected infrastructure itself.
16 International Mining | SEPTEMBER 2026