Caval Ridge Bridge Overheight Detection

Caval Ridge Mine experienced a critical bridge strike in 2024 when an overheight vehicle passed beneath the Peak Downs Highway overpass. The incident highlighted a significant safety risk which required accelerated action to prevent future incidents. Site required a rapid solution that could detect and warn overheight vehicles without false positives or missed detections and relay this information back to the site network.

Pipar designed a purpose built overheight vehicle detection system using long range 3D lidar technology. After evaluating mechanical, radar, and traditional overheight sensor options, lidar was selected as the only solution capable of meeting the road width, environmental, and reliability constraints.

The system uses multiple Ouster OS2‑128 lidar units positioned on either side of the bridge, providing two stage detection: an early warning zone and a final alarm zone. Dedicated processing hardware analyses vehicle profiles in real time, while reflective targets positioned on the other side of the road provide verification to ensure the system is operating correctly even in foggy or dusty conditions.

The solution was implemented in two stages:

1. Stage One: delivery of a fully self contained visual and audible warning system, compliant with Australian and TMR standards.
2. Stage Two:  Integration with BMA’s PLC, SCADA, and communications infrastructure for monitoring and control.

From project commencement to site delivery in three months, Pipar designed and built a robust solution that detects overheight vehicles and provides a two stage warning and alarm system. The result is a significant reduction in bridge strike risk, improved operator safety, and enhanced reliability of a major transport corridor. Since commisioning, the overheight detection system has prevented further bridge strikes, proving its value to the Caval Ridge Mine.