Fortescue’s 34,000-Tonne Ore Trains Get a Digital Upgrade from Knorr-Bremse

Fortescue has awarded Knorr-Bremse a long-term contract to modernise signalling across its heavy-haul rail network in Western Australia. The upgrade will introduce real-time train control and remote updates for ore trains weighing up to 34,000 tonnes.

In Western Australia, iron ore travels hundreds of kilometres from inland mines to coastal ports. The railway operates across desert terrain, where extreme heat and heavy loads place significant pressure on infrastructure and rolling stock. Fortescue has now selected Knorr-Bremse to modernise and digitally upgrade the signalling systems used across its extensive mining railway network.

"Across the globe, rail operators are determined to run their networks at higher performance levels while maintaining the highest standards of safety and reliability," said Dr Nicolas Lange, Member of the Executive Board of Knorr-Bremse AG responsible for the Rail Division.

"This creates significant opportunities for Knorr-Bremse to enhance infrastructure utilisation and efficiency through intelligent, digitally enabled signalling solutions. The Fortescue project is a strong example of how we are expanding our footprint in an attractive market while helping shape the future of smart, efficient, and sustainable rail transport."

Fortescue Rail Upgrade to Run Through Mid-2027

The modernisation programme will be introduced gradually and is expected to continue until the middle of 2027. The central part of the project is an upgrade of Fortescue’s existing Incremental Train Control System. Key infrastructure components will also move to KB Signaling’s ElectroLogIXS platform.

The new systems will provide real-time monitoring of track conditions, more flexible train control and additional operational data. This should help Fortescue respond more quickly when conditions change across its heavy-haul network.

Remote Updates for 34,000-Tonne Ore Trains

Some of the ore trains operating on the network weigh as much as 34,000 tonnes. Under the current system, trains may need to stop or enter a siding so that trip information can be adjusted following a route change.

Following the upgrade, dispatchers will be able to update train parameters remotely and in real time. This means trains will no longer need to stop to receive revised operational data. Knorr-Bremse says the change should reduce delays and improve the use of available railway capacity, particularly during congestion at loading points or when unexpected maintenance work affects the route.

New Rail Technology for Extreme Heat

Knorr-Bremse and Fortescue are also considering further technologies that could be added to the network. One option is Electro Code 6, a digital track circuit designed to provide more precise train detection. The companies are also looking at Rail TempEst, a system that measures rail temperatures in real time and supports decisions on safe operating speeds.

Temperature monitoring is particularly important in Western Australia, where extreme heat can affect rail condition and infrastructure reliability. More accurate data could allow Fortescue to manage speed restrictions while making better use of the network.

"Fortescue has consistently been at the forefront of adopting advanced rail technologies and proving their value under real heavy-haul conditions," said Jeff Baker, Managing Director of KB Signaling.

"By combining proven systems with new digital capabilities, we are enabling Fortescue to run its network in a more flexible, resilient, and data-driven way – supporting higher productivity today and sustainable growth in the future."

_{Source: Knorr-Bremse Press Release}