Summary
A Tier-1 iron ore producer in Western Australia required a unified monitoring platform spanning an entire mine-to-port export corridor: an open-pit mine, 780 km of heavy-haul railway, a port facility, and a product stockpile. Hypotenuse delivered a federated digital twin that integrates structural health data from all infrastructure domains into a single operational risk dashboard — enabling dynamic maintenance scheduling and corporate-level risk reporting.
Background & Context
The export corridor handles 85 Mtpa of iron ore. Structural integrity failures at any node — slope collapse, rail track failure, port jetty damage — create downstream production losses of $1.5–4M per day. Senior management required a single metric that could quantify infrastructure risk across the entire asset portfolio, enabling board-level reporting and insurance negotiations.
Sensor Deployment
Cross-Domain Integration
Hypotenuse's federated data platform integrates 14 disparate existing monitoring systems (including 3 different SCADA platforms, legacy safety control systems, and a rail track geometry measurement system) via custom API connectors and IoT edge gateways. Data is normalised and ingested into a unified time-series database at a central cloud processing node.
A custom ontology maps all sensor streams to a shared asset model, enabling cross-domain correlation analysis that was previously impossible. For example: the platform identifies the statistical relationship between mine blast vibration events, induced railway track displacement, and downstream stockpile settlement — a multi-domain causal chain that no single domain operator had previously quantified.
Decision Support Capability
The Hypotenuse Corridor Risk Index (CRI) aggregates 2,400+ sensor channels into a daily infrastructure health score reported to the executive team. Maintenance scheduling AI uses the CRI to optimise the sequence and duration of track maintenance windows, reducing interference with production scheduling.
An insurance risk module generates quarterly structural condition reports in the format required by Lloyds of London underwriters — demonstrating real-time condition evidence that underpinned a 12% premium reduction.
Key Outcomes & Results
Corridor Risk Reporting
First unified infrastructure risk metric across a 780 km export corridor
Maintenance Efficiency
AI scheduling reduced maintenance-related production delays by 31%
Insurance Premium
12% reduction based on demonstrated real-time condition monitoring
Cross-Domain Insights
4 previously unknown blast-vibration/track-damage correlations identified
Platform Integration
14 legacy systems unified into a single operational dashboard
Executive Reporting
Automated weekly board-level infrastructure risk summary — zero manual compilation
780km
Corridor length
2,400+
Sensor channels
31%
Maintenance delay reduction
85Mtpa
Throughput protected
Deployment Snapshot
Location
Pilbara, Western Australia
Throughput
85 Mtpa iron ore
Corridor Length
780 km
Infrastructure Nodes
4 (mine, rail, stockpile, port)
Sensor Channels
2,400+