A Repeater Decommissioning Left a Coverage Gap
Fulton Hogan's Bay of Plenty quarry site relied on a traditional radio repeater, held under third-party ownership, to provide long-range communications across the operation. That repeater was scheduled for decommissioning.
A replacement repeater solution was assessed, but the surrounding terrain and site layout meant the new repeater couldn't achieve the required coverage, and the original repeater's exact site location wasn't available to replicate. With long-range, dependable communication remaining critical for both safety and operational efficiency, Fulton Hogan needed an alternative that didn't depend on traditional repeater infrastructure.
An LTE-Based PoC Radio Deployment
Mobile Systems implemented an LTE-based Push-to-Talk over Cellular (PoC) radio solution using Motorola TLK series radios. This removed the dependency on local repeater infrastructure entirely, instead leveraging 4G/5G cellular networks to provide reliable coverage across the quarry and beyond.
Key capabilities delivered included wide-area LTE coverage eliminating reliance on repeater systems, over-the-air programming for remote radio management and updates, Wi-Fi fallback connectivity for site offices and depot environments, and rugged PoC radios built for demanding quarry conditions.
Reliable Coverage, Less Downtime
| Key Benefit | Outcome |
|---|---|
| Long-range communication | Teams communicate reliably across the entire quarry and between work areas, without reliance on repeater coverage. |
| Improved operational continuity | Communications remain consistent regardless of terrain or site layout. |
| Reduced downtime | Radios are managed and updated remotely, eliminating on-site reprogramming or equipment downtime. |
| Operational efficiency | Clear, instant communication between supervisors, plant operators, and site teams has improved coordination and workflow. |
| Scalable solution | The system can be expanded or redeployed as site requirements change. |
Interview with Ivan Cossey
"Simple cross over. Staff picked up the new technology quickly with a bit of training and use, the PoC radios are similar to traditional stuff."
"Coverage is excellent, I can be in another city and still have coms with the staff in BOP, clarity is fantastic, very clear."
"The improved communication has made a real difference to how we coordinate day to day. The caller ID feature is especially useful, as we can immediately see who is speaking when a call comes through, which cuts down confusion. We use the one-to-one private calling feature a lot as well, particularly when we need to pass on specific information without tying up the main channel. Being able to see who is online has also been really helpful, if someone's name isn't showing in the morning, we can quickly follow it up by phone to check whether their radio is on or if there's an issue."
"Being able to manage the radios remotely has saved us a lot of time. We no longer need to take radios into the shop for servicing or programming or take a truck off the road just to make changes. Now it's as simple as a quick phone call or text to Nathan, and updates can be pushed out to all the radios over the air. So far, we haven't had any failures, which has made the whole process easy and reliable."
"We've noticed much better clarity, in many cases it's even clearer than a phone call. The mobility side of it has been great as well; the radios are small and lightweight, so the guys are happy carrying them and don't complain about wearing them. The range and coverage have been excellent and being able to see who's online at any time is useful. Over-the-air updates have also been a big plus, as everything can be managed quickly without disrupting the team. The emergency feature is good."
"We haven't had any issues."
"Yes."
"Yes, definitely."
A Modern Solution That Overcame the Old Infrastructure's Limits
By partnering with Mobile Systems Limited, Fulton Hogan's Bay of Plenty operation implemented a communication solution that overcame the limitations of its previous repeater infrastructure. The LTE PoC radio platform delivers reliable long-range communications, simplifies radio management through over-the-air updates, and supports safe, efficient quarry operations regardless of site geography.
