Blog Archives | Ground Control

Critical national infrastructure is an increasingly attractive target for state-sponsored activists and extremist groups. Remote infrastructure – everything from outstations to wind farms, wellheads to pump stations, haul roads to transport hubs – is particularly vulnerable because of the challenges in creating robust security solutions in these locations. This blog post seeks to present a solution to these challenges, but first, let’s dig into the issues in more detail.

The Growing Threat to Remote Infrastructure

The vulnerability of utility and energy production sites to cyber attacks is well documented; from 2023 to 2024, US-based utilities experienced a 70% surge (Reuters). Less frequently reported is that physical attacks on infrastructure also rose 73% from 2020 to 2022 (Axios), with incidents including a gunfire attack on two substations in North Carolina, USA, which left 45,000 customers without power.

In Nigeria, in early 2024, the power sector faced escalating vandalism of high-voltage transmission infrastructure; incidents tripled during a 15 week span, including explosives being used to destroy transmission line towers (The Electricity Hub).

In Australia, thefts from unmanned construction sites reached a 10 year high in September 2024, with a 22% increase in theft-related offences during the same period (Herald Sun). And in the UK, the cost of theft of agricultural equipment escalated to an estimated £52.8 million in 2023, a 4.3% increase from the previous year (NFU).

In addition to a growth in isolated incidents is the underlying strategy to destabilize infrastructure, driven by alliances between state actors like Russia, and organized criminal gangs. These activities include sabotage, arson and cyber attacks, aimed at undermining critical infrastructure (The Guardian).

Attacks are increasing: companies, governments and individuals with hard-to-protect, high value assets are fighting a rising tide of criminal activity.

The Challenge of Traditional Security Measures

The infrastructure we’re describing here – transport, energy production, heavy industry – operates across vast areas, making it impractical to station physical security at every location which could be a target. Assuming a single security guard is stationed at a site for 8 hours a day, 7 days a week; the cost of an unarmed guard would be c. $3,600, and c. $6,000 for an armed guard (Deep Sentinel).

Statistically, most theft takes place after dark, and are more frequent in winter; long weekends and holidays are also attractive (Site Watch Group). Thus, 24 hour cover would be prudent at least over weekends, adding substantially to the cost.

Security-Guard-in-Remote-Location-shaded-blue

Another option is to use fences coupled with cameras and sensors to detect intruders, and provide real-time alerts to a remote monitoring center. The security personnel there can monitor multiple sites remotely, reducing on-site staffing costs. Upon receiving an alert, they can choose to dispatch security personnel to the affected site, alert local law enforcement or trigger some localized deterrent such as alarms, voice sirens or lights.

The pros of this approach is that it’s lower cost, delivers 24/7 surveillance, and can be rapidly and cost-effectively scaled up. However, it requires a reliable, secure and cost-effective means of transmitting the video stream (and potentially also audio and movement sensors). Within cellular connectivity this is pretty straightforward, but in a remote site, satellite is often the only viable option.

Remote-Surveillance-Smart-Fence-shaded-blue

Finding the Right Satellite Connection for Remote Surveillance

Satellite connectivity isn’t a homogenous blob. There are multiple radio frequencies used, and the type used strongly influences the form factor of the satellite transceiver. For example, people seeking broadband internet access over satellite – Starlink, Hughesnet, OneWeb etc. – will be using Ka-band, as this supports higher data rates, and there’s plenty of bandwidth available (i.e. limited congestion issues).

The drawback of Ka-band is that it is both susceptible to rain fade (signal loss in bad weather), and the antenna size is large, power hungry, and needs to be precisely positioned. This is not an issue for home installation, but in a remote outstation, there may be mountains, trees or the outstation itself preventing the ideal siting of the antenna.

The fix to this – phased array antennas which electronically steer themselves to optimal positions – has the drawback of consuming significantly more power. Indeed, it would be challenging to power any Ka-band antenna via a solar-powered battery, particularly for the sorts of continuous operation that a surveillance system requires.

Satellite Frequency Bands

Satellite services that operate in the L-band spectrum, on the other hand, have very small antennae, and low power requirements compared to Ka-band. Iridium and Viasat (previously Inmarsat) utilize L-band for data transmission, which makes them perfect for IoT applications where the data requirements are lower, and a small, discreet, battery-operable antenna is an asset – sometimes a necessity. L-band transmissions are unaffected by weather conditions, and very hard to intercept, making them ideal, in principle, for mission critical applications like remote surveillance.

However, video streaming from remote, potentially unpowered locations, is an awkward fit for both Ka- and L-band. It’s a high bandwidth transmission, but as discussed, high bandwidth satellite services are power hungry, easy to identify (and therefore to put out of action), and difficult to position. L-band fixes all those challenges, but to send video over L-band, which is a much more constrained frequency band, is very expensive.

Until now…

A Breakthrough in Remote Video Surveillance

There have been two key developments that have made it possible to send video over an L-band satellite connection cost-effectively. The first is the advent of low bandwidth video. Our partner Videosoft has developed video compression and transmission technology that delivers real-time, low-bit rate video. They’ve coupled this with an image enhancement feature that lets users specify and download high-res pixels from an area of interest in a scene.

Videosoft’s technology works with most off-the-shelf hardware, including video cameras, CCTV, audio microphones, GPS tracking antennae, and other I/O devices.

The second development is the availability of midband (higher throughput) transmissions in the L-band spectrum; notably Viasat’s IoT Pro service, and Iridium’s Certus 100 service. The latter is particularly well suited to remote surveillance because the satellites are in Low Earth Orbit, which means the latency is very low – critical when you need real-time alerts if a facility has been penetrated, or an asset is moving outside of schedule.

Additionally, Iridium has a cross-linked network of 66 satellites, which means you don’t need to point your antenna at the satellite; if your facility or asset is in a wooded or mountainous area, this could be a critical advantage.

RockREMOTE Rugged: A Simple and Secure Solution

There are a number of Iridium Certus 100 transceivers available – we design and build several ourselves – but the one we’ve focused on for remote surveillance is the RockREMOTE Rugged. This is because, most importantly, it has the compute power to natively run the Videosoft program without needing any additional hardware. It’s simply a matter of plugging your camera into the RockREMOTE, and working through some simple config steps to get started.

RockREMOTE Rugged is very easy to install; it’s IP67 rated, and designed for permanent outdoor installation in harsh environments. Its omni-directional passive antenna is small and discreet, making it harder to identify by bad actors.

Thus, securing a remote site becomes smarter and more cost effective. Choose from a very wide range of cameras, audio equipment, motion detectors etc., then plug them in to the RockREMOTE Rugged. The onboard Videosoft technology will compress the data so it can be sent cost-effectively over the Iridium Certus 100 network, in real-time, to your remote monitoring center.

A Smarter Approach to Remote Security

Protecting remote infrastructure has never been more critical – or more challenging. While traditional security measures struggle to balance cost and coverage, the combination of low-bit rate video, real time image enhancement, and power efficient satellite connectivity presents a game changing solution.

With RockREMOTE Rugged and Videosoft’s technology, organizations can deploy surveillance systems that are reliable, cost effective, and optimized for remote environments. Whether safeguarding critical national infrastructure or protecting high value assets, this technology ensures security teams have the visibility they need, when they need it most.

Smarter Security for Remote Infrastructure

Protect your critical sites with real-time video surveillance over satellite. Our RockREMOTE Rugged, combined with Videosoft’s low-bandwidth streaming, delivers cost-effective, 24/7 monitoring, even in the most challenging locations.

Complete the form, or email hello@groundcontrol.com to learn more. We’ll reply to your inquiry within one working day.

Undersea internet cables are essential for global communications and economic security. The entire global network of cables is more than half a million miles long and comprised of more than 200 independent but interconnected systems. These cables span vast distances, connecting continents and enabling everything from international internet services to military communications. But with increasing geopolitical tensions and the growing importance of digital infrastructure, the threat to these cables has risen on the international agenda.

The strategic importance of undersea cables, which carry 99% of international telecommunications, makes them attractive – and vulnerable – targets.

In January 2025, the Royal Navy closely monitored the Russian vessel Yantar, officially an ocean research ship but considered a spy ship, as it entered UK waters and mapped underwater infrastructure.

Additionally, a NATO flotilla, including ships from the Netherlands, Germany, and France, assembled off Estonia to protect undersea cables in the Baltic Sea from potential sabotage, primarily by Russia.

Guard and patrol vessels play a pivotal role in deterring and responding to potential threats, ensuring the integrity of essential communication networks.

Data from the TeleGeography Submarine Cable Map shows that damage to undersea cables is a common occurrence. According to a report by the International Cable Protection Committee (ICPC), around 300 cable breaks are reported every year. Most of these are accidental, caused by fishing trawlers, ships’ anchors, or natural events like earthquakes. However, the risk of deliberate attacks or sabotage by state or non-state actors is also increasing.

The potential for geopolitical tensions to spill into the maritime domain has been highlighted in various reports. For instance, the United States Department of Defense (DoD) has raised concerns about the vulnerability of critical undersea infrastructure to foreign adversaries. This type of attack can have devastating effects on global data flow, cybersecurity, and national security.

Internet traffic, military transmissions and financial transactions all depend upon submarine cables, so any disruption can cause significant economic damage, loss of access to critical services, and widespread instability in communication.

The Role of RockFLEET in Securing Submarine Cables

Guard boats are increasingly deployed as vital protectors of undersea cabling infrastructure. These guard boats, often repurposed fishing vessels, act as sentinels over subsea cables, ensuring their security by warning nearby vessels to keep a safe distance.

Tracking guard boats efficiently in remote and challenging maritime environments requires an advanced tracking solution. RockFLEET is a compact, robust, and highly reliable tracking device designed specifically for use in harsh maritime conditions. It operates through satellite-based communication via the global Iridium network, ensuring seamless tracking of guard boats even in areas with no cellular coverage, anywhere in the world.

This capability is essential as guard boats often patrol vast stretches of ocean far from terrestrial networks. With RockFLEET, maritime authorities and operational teams can monitor the precise location of each guard boat, ensuring the vessels are where they need to be to protect the cables effectively.

Three Ways RockFLEET Supports Guard and Patrol Vessels

Real-time Positional Data

One of the key features of RockFLEET is its ability to provide real-time positional data, which allows maritime coordinators to track the movement of guard boats and assess their effectiveness in securing undersea cables. If a guard boat drifts away from its designated patrol zone, RockFLEET alerts the operational team, enabling quick corrective action. This constant monitoring ensures that no section of the subsea cable remains unprotected due to navigational drift or unforeseen circumstances.

Estimated Arrival Times

Another critical function of RockFLEET is providing estimated arrival times (ETA) for guard boats. When repositioning guard boats due to shifting threats, adverse weather conditions, or maintenance schedules, knowing the vessel's precise ETA is crucial. RockFLEET transmits accurate ETA data, allowing for better planning and coordination. This information helps ensure that there are no gaps in cable coverage and that another vessel is available to take over if one needs to leave its position.

Enhanced Vessel Safety

Safety is also a significant concern for guard boat crews. Since these vessels often operate in remote and sometimes hazardous conditions, having a reliable tracking system ensures that their locations are known at all times. In case of an emergency, RockFLEET provides real-time location updates, enabling rapid response and assistance from support teams. This enhances the overall security of both the vessels and the critical cabling infrastructure they protect.

The Future of Undersea Cable Security

As the threats to undersea cables continue to evolve, governments, cable operators, and multinational organizations are increasingly prioritizing the security of this infrastructure, given its direct impact on everything from national security to economic stability. New initiatives like the UK’s ‘Nordic Warden‘, which aims to track the movement of vessels suspected of malicious damage, should enable faster response times.

Guard boats and patrol vessels in their preventative capacity will remain an essential part of this response. RockFLEET plays an essential role in ensuring the effective tracking and monitoring of guard boats tasked with the protection of undersea cables. By providing accurate location tracking, monitoring movement, estimating arrival times, and enhancing overall vessel safety, RockFLEET helps to safeguard the vital cable infrastructure that underpins global communication and commerce.

Protect Critical Infrastructure with Smarter Maritime Monitoring

As threats to undersea cables and maritime assets increase, guard and patrol vessels play a crucial role in safeguarding global communications. Our advanced satellite tracking and monitoring solutions ensure these vessels operate with maximum efficiency, real-time situational awareness, and enhanced safety – no matter how remote the mission.

Equip your fleet with the technology to stay ahead of emerging threats. Contact us today to learn how our solutions support maritime security operations. Complete the form, or email hello@groundcontrol.com.

What is D2D?

D2D refers to the ability for an unmodified device – such as a cellphone – to access satellite connectivity. This was pioneered by Apple and Globalstar as they partnered to provide an emergency satellite communication service for iPhone users in 2022.

How Does D2D Work?

There are two ways D2D can be delivered. The first is by building a chipset into the device that allows it to access a specific satellite network. This is the option chosen by Apple, and its satellite network partner Globalstar. The benefit of this approach is that Globalstar has licensed radio spectrum that allows it to provide a service anywhere where it has a satellite overhead. The downside is that the device can only communicate with a single satellite network.

The second way to deliver D2D is to adapt the satellites themselves so that they are compatible with the communication protocols already in use by cellphones and other devices – i.e. 4G, 5G etc. This is the approach chosen by Starlink, AST SpaceMobile and Lynk, all of whom are in the process of launching satellites compatible with terrestrial network communication standards.

The benefit of this approach is that, in theory, all compatible satellite networks are available to the cellphone user as simply another network on which to roam, and they can do so depending on what their commercial agreement is with their usual network service provider (e.g. Vodafone, AT&T etc.).

The downside is that because these are new satellite networks, they do not have licensed radio spectrum through which to deliver their service; this is already distributed among older, more established satellite constellations. So to deliver service, the new satellite network operators need to partner with a terrestrial network operator to ‘borrow’ some of their licensed radio spectrum. Services are only available where these partnerships exist, so they are not global. Starlink, for example, has partnerships in 10 countries; outside of these countries, it cannot provide service.

How Could D2D Benefit Lone Workers?

In 2021, we asked lone workers across multiple industries if, as part of their job, they sometimes or often travelled out of cellular coverage. 51% responded yes. We then asked about the implications of this; did they ever feel unsafe, for example, or been unable to send or receive a message when they needed to.

Statistics on Lone Worker Safety

As the graph illustrates, lone workers operating in areas without voice, text or internet services feel – and are – more vulnerable. 15% of the overall workforce are considered lone workers, and NSC data indicates that working alone increases both the likelihood of incidents, and the severity of adverse outcomes.

Although we can’t draw a parallel, it’s striking that industries with a high number of lone workers – Utilities & Renewables, Oil & Gas, Forestry, Emergency Response, Community Healthcare – are also struggling with staff retention.

80% of Oil & Gas workers are considering leaving the industry
The US Forest Service has lost nearly half of its permanent employees in the last three years
In the UK, 32% of social care workers leave their roles every year – an increase of 9.1% over the last decade.

While it’s not a silver bullet, the benefits of lone worker monitoring technologies are well documented: improved safety outcomes and staff morale, leading to greater staff retention, and saved costs in recruitment and insurance premiums.

An estimated 2.3 million lone workers in Europe, North America, and Australia & New Zealand now have access to a lone worker safety solution, with the market estimated to grow at a rate of 7.1% between 2024 and 2029 – further indication of the value of these platforms.

But if they can’t be accessed because the worker is outside cellular coverage, they fail. D2D with its ability to confer internet access to any compatible cellphone with a relevant commercial agreement, unlocks the ability to access these platforms from very remote locations where cellular coverage is nonexistent.

Why Your Cell Phone May Fail You

The problem with D2D is not the service, it’s the cellphone. Relying on a standard smartphone for emergency or indeed routine satellite communication comes with significant weaknesses, especially when it comes to the device’s physical vulnerabilities. Here’s why your phone may not be the most reliable option when you need it most.

Overheating and
Thermal Shutdowns

Satellite connections require the phone to transmit at higher power levels, which generates more heat than cellular communication. Many phones will automatically shut down when internal temperatures exceed safe limits, leaving users without a means of communication.

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Drop and
Impact Vulnerability

A cracked screen or internal damage from a fall can render a phone unusable, preventing emergency communication. Even flagship smartphones can shatter from waist-high drops, whereas ruggedized satellite communicators are built to withstand extreme impacts.

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Battery Drain and Cold Weather Failure

Phones in satellite mode will often use higher transmission power and spend more time searching for signals, draining the battery faster. Further, cold weather severely affects lithium-ion battery performance.

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Lack of Physical Controls for Emergency Use

In emergency situations, speed matters. Unlike dedicated satellite devices, which often feature an SOS button that can be activated instantly, smartphones rely on touchscreen controls that may be difficult to use with wet, cold, or gloved hands.

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Weak Antenna and Poor Signal Reception

Smartphones' internal antennas are optimized for terrestrial networks, meaning signal reception in satellite mode will often be weaker and less reliable. Dedicated satellite communicators feature larger antennas that ensure consistent connectivity even in difficult environments.

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The Safer Alternative: Dedicated Satellite Communicators

In life-critical situations, reliable communication is essential. The RockSTAR rugged satellite communicator outperforms standard devices with extended battery life, superior durability, and truly global coverage. Designed for extreme environments, it ensures emergency responders, remote workers, and adventurers stay connected when it matters most. With near-instant messaging and a one-button SOS feature, help is always within reach.

The RockSTAR offers a ≈12-month battery life on a single charge, operates in extreme heat and cold, and withstands rough conditions. With ≈10-second latency, it provides real-time tracking and updates. Its easy-to-reach SOS button ensures immediate distress signals, making it the ultimate safety tool for remote and high-risk environments.

RockSTAR is more than just a rugged satellite tracker; it’s a powerful solution for real-time visibility, safety, and communication in the world’s most remote environments. When paired with Cloudloop Tracking, it offers an intuitive platform for monitoring, messaging, and emergency response, ensuring that lone workers, field teams, and mission-critical personnel remain connected no matter where they operate.

For organizations with specialized requirements, we work with trusted partners like Locate Global and JCSys, who provide advanced functionality for healthcare, emergency response, and military applications.

Additionally, our well-documented API allows operators to seamlessly integrate location, messaging, and event data into their own preferred platforms, giving them complete control over their tracking and communications ecosystem. Whether using Cloudloop Tracking or integrating with an existing system, RockSTAR ensures reliable, global connectivity for those who need it most.

Get In Touch

If we can support your efforts to improve lone worker safety and communication, please get in touch. We have delivered satellite-enabled tracking and messaging services since 2005, and provide support to a diverse set of users – from soldiers to remote site inspectors.

Email hello@groundcontrol.com to tell us about your requirements, or complete the form, and we’ll be in touch within one working day.

In today’s interconnected world, digital threats have reached a scale never seen before.

In 2023, rising global tensions led to a surge in cyber threats and disruptions to critical infrastructure worldwide. Escalating conflicts – such as those involving Ukraine and Russia, Israel and Hamas, and nations in the South China Sea – motivated hackers to exploit critical infrastructure for control and financial gain. Globally, ransomware incidents are increasing across every continent, as the map shows. At the same time, ransomware attacks targeted more industrial organizations, with reported incidents increasing by nearly 50 percent [Dragos report 2023].

Illustration showing the number of reported ransomware attacks by continent

Cyber attacks can target everything from financial institutions to healthcare systems, transportation networks and power grids – and it’s of increasing concern to the general public. In January 2025, Ground Control conducted a survey of 500 US adults which revealed that over 65% were concerned about cyber attacks on critical national infrastructure, with 70% having limited to no confidence that essential services are protected from cyber attacks.

Utility providers are now facing an alarming new reality where cyber attacks increasingly threaten the safety of their operations. Indeed, Utilities is the second most targeted industry for ransomware attacks, experiencing a 270% increase in data violation cases between 2020 and 2023.

The 2021 Colonial Pipeline Attack

The 2021 Colonial Pipeline attack served as a wake-up call, underscoring the vulnerability of the utility sector to cyber threats. Hackers used a virtual private network (VPN) to infiltrate the pipeline’s control systems, causing widespread fuel shortages across the US East Coast. The incident led to a ransom demand of $5 million, which was ultimately paid to regain control of the pipeline.

The financial costs of data breaches are staggering. According to IBM’s 2021 report, the average cost of a data breach rose to $4.24 million. These costs go beyond the immediate exposure of data and include downtime, loss of revenue, and long-term reputational damage. Utilities must be proactive in defending against such threats to avoid crippling financial losses and operational disruptions.

The Hidden Vulnerabilities in Utility Networks

Utility companies depend heavily on SCADA (Supervisory Control and Data Acquisition) systems to monitor and control infrastructure. These systems collect and transmit data from Remote Terminal Units (RTUs), often located in remote or hard-to-reach areas. However, these RTUs present a significant security vulnerability. With 90% of utility customers reporting “limited to no visibility” into their industrial control systems, once a hacker gains access, they can easily monitor, manipulate, and potentially sabotage critical infrastructure [Dragos report, 2020].

It’s crucial for utilities to address this blind spot and implement solutions that safeguard the data extracted from RTUs and transmitted to SCADA systems.

How Remote Sites Become Prime Targets for Cyber Attack

Remote utility sites, such as offshore wind farms and oil and gas pipelines, are particularly vulnerable to cyber threats. With limited or no access to terrestrial connectivity such as cellular or fiber networks, these remote locations are often the last to receive attention when it comes to cybersecurity. Cybercriminals exploit this vulnerability, targeting sites that lack secure and reliable communications infrastructure. The risk is further compounded by the fact that many utility providers rely on lone workers or contractors to maintain and monitor these remote operations, leaving these sites exposed to cyber threats.

The Role of Satellite Connectivity in Improving Data Security in Utilities

Satellite connectivity has some inherent advantages over cellular networks when it comes to data security; with limited ground infrastructure, it’s less susceptible to physical attacks, and signals are more difficult to intercept. There’s also a reduced risk of infiltration via local Internet Service Providers (ISPs) as these are typically bypassed by satellite communications. But with satellite services diversifying, and more networks being launched, there are now many varying options for data security.

Our Recommended Solution

TSAT is a satellite-based communication system designed specifically for secure, resilient remote monitoring and control of SCADA systems. Unlike traditional ground-based communication networks which can be easily compromised by cyberattacks, the TSAT satellite communication solution provides a more secure and tamper-resistant infrastructure.

How TSAT Protects Critical National Infrastructure

The ability to remotely monitor and control systems via satellite communication is essential in maintaining the integrity of critical infrastructure. TSAT’s secure transmission capabilities ensure that communication between central control centers and field sites remains uninterrupted, even in the face of large scale cyber threats.

As mentioned earlier, satellite connectivity has several security advantages over terrestrial networks; a reduced attack surface, plus limited reliance on the public internet to move data being two examples. However, most satellite networks, whether in low earth orbit or geostationary orbit, leverage the internet to move data from the ground station to your application. This process iprotected via VPNs and firewalls, which, in addition to AES-256 encryption of data, satisfies most organizations’ requirements.

Diagram showing how low earth orbit satellites work

Critical National Infrastructure, however, often benefits from, and may even require, complete independence from public infrastructure, and that’s how private satellite networks like TSAT function. Here, as shown in the diagram below, data from the satellite comes to a ground station on your premises, rather than into the satellite network’s ground station. This means that your data is air gapped from external networks.

How private satellite networks work

Part of the TSAT service is dedicated satellite bandwidth that prevents interference from other users, ensuring consistent and secure connectivity. TSAT also has no reliance on GPS timing, making it immune to GPS jamming. What’s more, its geo-redundant hubs and frequency diversity allow terminals to automatically switch frequencies if interference occurs, ensuring uninterrupted communication.

Real-World Applications of TSAT

A major energy infrastructure operator connects gas markets between the UK and continental Europe, managing a bi-directional gas pipeline with terminals in two key locations.

To maintain operations, a series of pressure and temperature sensors must continuously transmit data to the company’s SCADA system, which authorizes gas transmission.

If this sensor data becomes unavailable, production must halt, and gas venting procedures are required; an expensive process with significant operational and environmental impact.

To ensure real-time, reliable sensor data transmission, the company requires multiple active communication pathways at all times. They maintain a dedicated fiber connection alongside two satellite connections, all tasked with delivering critical data to the SCADA system. To further reduce reliance on public infrastructure, they have implemented TSAT ground stations at each terminal, eliminating the need for internet-based backhaul.

Each satellite link consists of two antennas: a hub and a remote. Typically, the remote antenna is positioned in a more isolated location near the sensors, transmitting data to the hub at the operations center. However, in this case, both satellite dishes are located in close proximity but pointed at different satellites, ensuring redundancy in case of a satellite failure.

Additionally, the company has implemented a unique failsafe: at each terminal, the hub and remote antennas are pointed at opposing satellites relative to the other terminal. This setup provides resilience against localized weather disruptions or signal degradation.

This system has been in place for over 16 years, with hardware upgrades along the way, and in that time, the satellite connectivity has never failed. Ground Control supports the company with a full turnkey service, including setup, training for routine maintenance, and periodic site visits for system health checks.

Embracing Satellite Technology for Cyber Defense

With the growing threats posed by cyber warfare, the time to act is now. TSAT offers a solution that is robust, resilient, and adaptable to the evolving threats of the digital age to utilities. It’s time for utility providers and organizations worldwide to adopt secure satellite enabled technologies, like TSAT, to protect their most vital assets and ensure uninterrupted services to customers. The question isn’t whether you can afford to adopt this technology – it’s whether you can afford not to.

Can we help?

Our satellite-enabled solutions offer robust security features designed to protect your critical data, coupled with reliable connectivity.

Partner with us to explore satellite solutions that safeguard your operations and enhance your secure data transfer capabilities.

Complete the form or email hello@groundcontrol.com and we’ll get back to you within one working day.

Securing IoT Data: Why Satellite Connectivity Matters

As industries become more reliant on IoT technology to monitor and manage remote operations, the security of IoT data has never been more critical. From energy infrastructure to national utilities, Critical National Infrastructure (CNI) organizations handling sensitive data are prime targets for cyberattacks. While cellular and terrestrial networks have long been the backbone of connectivity, their vulnerabilities are increasingly being exposed.

This is where satellite connectivity stands apart. Satellite networks offer global coverage, operate independently of local terrestrial infrastructure, and provide enhanced security features to mitigate cyber threats. However, like any technology, they’re not without risk. Our latest report, How Satellite IoT Connectivity Supports Data Security Measures, delves into the specific security challenges and solutions that satellite connectivity offers for IoT applications.

Read Data Security Report

82%

say CNI organizations aren’t investing enough in cybersecurity

62%

would feel safer if CNI organizations had backup satellite connectivity

93%

of CNI organizations report an increase in cyber threats

Key Insights from the Report

1. The Growing Cybersecurity Threat to IoT Networks

Critical national infrastructure sectors, including energy, utilities, and transportation, are facing an increasing number of cyber and physical threats. Attacks on property, plus DNS poisoning, DDoS attacks, and Man-in-the-Middle attacks are just a few of the risks that can disrupt operations or compromise data integrity. Organizations must adopt a proactive security strategy to safeguard their IoT deployments.

2. Why Satellite IoT Offers a More Secure Alternative

Unlike terrestrial networks, satellite connectivity does not rely on local ISPs or cellular towers, making it less susceptible to traditional cyberattacks. High encryption standards, private network options, and advanced threat detection make satellite communications a strong choice for securing IoT data.

3. How to Mitigate the Limitations of Satellite Data Security

While satellite networks provide strong security advantages, they are not immune to threats. The report explores best practices, such as end-to-end encryption, network segmentation, and failover protection, that organizations can implement to further strengthen their security posture.

4. Expert Insights from Leading Satellite Providers

The report includes expert perspectives from industry leaders, including Viasat, TSAT, and Iridium, highlighting the measures these providers take to enhance security for IoT applications. From private satellite networks to real-time monitoring and AI-powered threat detection, these insights help organizations make informed decisions about securing their satellite IoT deployments.

If your organization relies on IoT connectivity for critical operations, understanding the security implications of your network choice is essential. Our comprehensive report provides the insights and strategies you need to enhance your security posture and protect your data from emerging threats.

Download the full report now to learn how satellite can be a key component of your IoT security strategy.

Discover the level of confidence the general public has in CNI organizations’ data security measures
Learn from industry leaders about best practices for securing critical infrastructure
See how past attacks have exploited vulnerabilities in terrestrial networks
Compare security measures across different satellite networks
Get the knowledge you need to make informed choices about secure connectivity.

Read Data Security Report

Can we help level up data security for your organization?

We’ve delivered connectivity solutions for critical national infrastructure projects for over 20 years. Our expertise in satellite technology, combined with a deep understanding of mission-critical applications, allows us to tailor solutions to meet your specific needs.

By partnering with Ground Control, you gain access to a team that is not only well-versed in the latest satellite technologies but also dedicated to helping you secure your communications, mitigate risks, and ensure that your operations stay connected no matter the challenges.

Complete the form, or email hello@groundcontrol.com to be connected to one of our expert team.

Manufacturing and Heavy Industry operations around the world rely on their machinery to get the job done, efficiently and effectively. The cost of equipment failure and the resulting unplanned downtime has serious consequences for the bottom line, with medium unplanned downtime costs approximately $125,000 per hour. When inflationary pressures, supply chain demands and raw material costs are factored in, unplanned downtime costs for Heavy Industry were calculated as $59 million per year in 2023.

Faced with the need to minimize the business impact of unplanned downtime for critical equipment, industries with heavy assets and significant downtime costs, such as oil & gas and mining, are leading the way in adopting Predictive Maintenance solutions.

By incorporating satellite connected IoT sensors, Heavy Industries operating in remote locations can reliably monitor machinery in real time and react quickly to avoid equipment failures and keep assets operational. The data from satellite-connected sensors on equipment forms a vital component of deploying Predictive Maintenance programs in industries with high asset costs.

What is Predictive Maintenance?

Predictive Maintenance (PdM) is a proactive, data-driven approach that uses advanced technologies – such as condition monitoring, machine learning (ML) and IoT devices – to anticipate equipment failures and schedule maintenance before disruptions occur. By analyzing real-time data from sensors installed on machinery, PdM identifies early signs of wear, faults, or deterioration, enabling timely intervention to prevent costly downtime.

Unlike time-based or reactive maintenance, PdM optimizes equipment performance by triggering maintenance tasks only when specific conditions indicate a need. This approach improves equipment reliability, reduces maintenance expenses, and extends the lifespan of assets. AI-powered analytics and IoT-enabled sensors track key metrics like temperature, pressure or vibration, providing continuous insights into machine performance. When thresholds are exceeded, PdM systems issue alerts or initiate maintenance work orders.

The goal of PdM is to enhance operational efficiency by minimizing unplanned downtime, lowering maintenance costs, and ensuring asset reliability. Industries such as manufacturing, energy, and transportation rely on PdM to align maintenance activities with actual equipment conditions, maximizing productivity and supporting cost-effective, sustainable operations.

What is the Difference between Predictive and Preventive Maintenance?

Although often used interchangeably, Predictive Maintenance (PdM) and Preventive Maintenance (PM) are distinct approaches to equipment upkeep, each suited to different operational needs.

Preventive Maintenance follows a scheduled approach, performing maintenance at regular intervals based on time or measurable usage units, such as engine hours or production cycles. This method ensures equipment is inspected and maintained before issues arise, but it does not consider the actual condition of the asset.

For instance, a Mining operation may replace drill components every six months, regardless of whether those components show signs of wear. While this minimizes the chance of failure, it may result in premature replacements or unnecessary downtime.

Predictive Maintenance leverages real-time data from IoT sensors and advanced analytics to monitor the actual condition of assets. Maintenance is performed only when necessary, based on insights into potential failures or performance degradation.

For example, IoT sensors on a Combine Harvester may detect rising temperatures or irregular vibrations, indicating wear and tear. Predictive maintenance enables technicians to address the issue before a failure occurs, minimizing downtime and repair costs.

Comparing the Two Approaches

Aspect

Preventative Maintenance

Predictive Maintenance

Basis for Maintenance

Time or Usage Intervals

Real-Time Condition Monitoring and Analysis

Frequency

Regular, Fixed Schedule

As Needed, Based on Data Insights

Costs

Lower Initial Costs, Higher Cumulative Costs

Higher Initial Investment, Lower Long-Term Costs

Downtime

May Require Equipment Stoppage

Often Avoids Downtime by Scheduling During Low-Impact Periods

Efficiency

May Result in Unnecessary Maintenance

Targets Specific Issues, Optimizing Resources

Types of Predictive Maintenance

There are three distinct types of Predictive Maintenance: Indirect Failure Prediction, Anomaly Detection, and Remaining Useful Life (RUL). Each approach differs in its desired objectives, the analytical methods used, and the type of information output provided.

Image adapted from the IoT Analytics Asset Performance & Predictive Maintenance Market Report 2023–2028

Indirect Failure Prediction
Estimates equipment health by calculating a ‘health score’ based on known maintenance requirements, operating conditions and historical performance data. When sufficient data is available, supervised machine learning can be applied to refine the predictions. This approach is scalable since it relies on manufacturer specifications, and it is cost-effective because it uses existing sensors.

Its dependence on large volumes of historical data may render it unsuitable for industries like heavy machinery, where high downtime costs necessitate more immediate and accurate insights.

Anomaly Detection
Identifies potential failures by detecting deviations from normal operating conditions in real time. Unlike methods that require historical data, it relies on current sensor data, making it particularly suited to organizations without extensive machinery usage records. This approach improves predictive accuracy by considering real-time environmental and operational factors rather than predefined maintenance parameters set by the manufacturers.
The risk of false positives can pose challenges, as unnecessary alerts may disrupt operations and complicate machine learning algorithm performance.

Remaining Useful Life (RUL)
Focuses on predicting the time left before equipment failure based on specific machine metrics such as operational hours, distance traveled, or activity cycles. By analyzing sensor data, this method identifies condition indicators that highlight whether the equipment is performing as expected or if faults have accelerated its degradation. RUL models are trained using system data collected under known conditions and applied to predict outcomes under new or variable circumstances.

While this method is highly robust and reliable, it requires detailed, high-quality data for accurate predictions, making it particularly effective for critical equipment in complex environments.

The Benefits of Predictive Maintenance

Predictive Maintenance brings many benefits to organizations through its advanced approach to equipment upkeep, using technology and data analysis to improve asset reliability and efficiency. By identifying potential issues before they lead to failures, PdM helps organizations reduce downtime, optimize resources, and maintain safer working environments.

Research, including findings from the US Department of Energy, highlights the tangible impact of Predictive Maintenance. Compared to preventive maintenance programs, it offers cost savings of 8% to 12%, and when compared to reactive maintenance, cost savings increase to 30% to 40%. These programs also enable a reduction in maintenance costs by 25% to 30% and minimize equipment breakdowns by 70% to 75%.

In addition to cost savings, PdM improves operational efficiency by reducing downtime by 35% to 45% and increasing production capacity by 20% to 25%.

40%

Cost Savings

30-45%

Downtime Reduction

75%

Fewer Equipment Breakdowns

How to Implement Predictive Maintenance

1. Establish Baselines and Data Collection

Baseline performance metrics are identified for the assets by monitoring its condition to set the normal performance benchmarks. Once the baseline is established, sensors are installed to capture real-time data, enabling continuous performance monitoring.

2. Install IoT Sensors on Equipment

IoT sensors are installed on critical equipment to monitor various parameters such as vibration, temperature, pressure, and noise. These sensors continuously collect data on the equipment’s condition and the data gathered is then transmitted to a centralized system for analysis.

3. Data Integration and System Setup

The data collected from the IoT sensors needs to be integrated with the PdM system. This involves connecting the sensors to a computerized maintenance management system (CMMS) or a remote dashboard which allows for real-time monitoring and data analysis.

4. Set Maintenance Thresholds and Automate Alerts

Organizations need to define thresholds for acceptable performance levels. When these thresholds are exceeded, the system automatically triggers maintenance alerts, enabling timely interventions before equipment failure occurs.

5. Select and Implement the Right Analytics Tools

An analytics platform is required to handle the large volumes of data, apply predictive models, and generate actionable insights. Machine learning and AI algorithms are crucial for analyzing sensor data and predicting future equipment failures based on historical data.

6. Develop Predictive Models and Train the System

Predictive models are developed using historical data, maintenance logs and sensor data to forecast future equipment behavior. These models are trained to identify patterns in the data that may signal the onset of failure.

7. Integration with Existing Maintenance Systems

The PdM system is integrated with existing workflows, maintenance management systems, and enterprise resource planning (ERP) systems. This enables seamless communication across platforms and allows for data-driven decision-making.

8. Monitor and Optimize the Program

After implementation, the PdM program should be monitored to evaluate its effectiveness. Continuous data collection and model refinement will help improve prediction accuracy over time.

Industrial Applications of Predictive Maintenance

Predictive Maintenance is becoming increasingly common practice in asset-intensive industries that depend on their large, complex machinery. For industries with assets in remote locations or critical communication requirements, satellite connected IoT devices can transmit real-time sensor data for PdM programs.

Energy and Utilities

The risk of equipment failure in energy production and utilities management can lead to significant financial losses and customer dissatisfaction. Power plants, wind farms, and utility grids employ PdM programs to ensure the continuous operation of critical assets like turbines, generators, and transformers. IoT sensors monitoring parameters such as vibration, temperature, and pressure are used to detect early signs of failure.

By analyzing these data points in real time with advanced predictive models, utility providers can prevent catastrophic failures, optimize energy production, and ensure compliance with regulatory standards. This is particularly important in industries where unexpected downtime can have widespread consequences on both financial performance and customer trust.

Railways and Transportation

PdM is crucial in the transportation industry for ensuring the safety and reliability of infrastructure such as railway tracks, trains, and airport ground equipment. IoT sensors on trains and other critical assets monitor parameters like pressure, temperature, and vibration to detect early signs of wear or failure.

For example, PdM can be used to monitor brake systems or detect track deformations, preventing accidents and service interruptions. By integrating sensors with automated maintenance management systems (CMMS), transportation companies can schedule repairs before a component fails, enhancing passenger safety and reducing operational disruptions.

Oil and Gas

In remote locations such as offshore platforms or desert pipelines, Oil and gas operations face unique challenges in maintaining equipment. PdM is highly beneficial in these situations, as it helps companies remotely monitor the condition of critical machinery like pumps, compressors, and valves.

Satellite-connected IoT sensors track parameters such as pressure, temperature, and vibration to detect signs of imminent failure. Real-time data is sent to cloud-based platforms for analysis, and predictive algorithms generate alerts to maintenance teams, allowing them to address issues before they result in costly downtime or safety hazards.

Mining

With Mining machinery operating in harsh conditions, the risk of unexpected breakdowns can lead to costly delays and safety hazards. Predictive maintenance helps to monitor heavy equipment such as crushers, drills, and loaders, which are critical to mining operations.

Satellite-enabled IoT sensors measure variables like temperature, pressure, and vibration, providing continuous health checks of the machinery. Predictive models analyze these data streams to identify wear patterns and predict when maintenance is required.

Sensor Technologies in Predictive Maintenance

Predictive Maintenance utilizes a range of sensor technologies to monitor the condition of equipment and to detect and address potential failures before they lead to unplanned downtime.

Infrared Thermography

Also known as thermal imaging, infrared cameras identify heat spots which can indicate issues such as friction, electrical resistance, or misalignment in mechanical systems. It is particularly valuable in identifying worn-out components or malfunctioning circuits that tend to overheat.

Infrared thermography allows for real-time monitoring without disrupting machine operation and is frequently used in industries like power generation to track turbine blade conditions and ensure equipment runs efficiently.

Acoustic Monitoring

Using specialized equipment, maintenance personnel can detect ultrasonic or sonic emissions from machinery, which may indicate leaks, electrical discharges, or mechanical wear. Sonic monitoring is typically applied to lower-speed equipment, while ultrasonic analysis is more accurate and applicable to both low- and high-speed machinery.

Ultrasonic analysis is widely used in industries like construction and heavy equipment operations, where hydraulic systems and machinery require constant monitoring to ensure seamless operation and prevent project delays.

Vibration Analysis

Sensors track vibration patterns that help technicians identify potential issues like misalignment, unbalanced components or bearing failures in high-speed rotating equipment, such as motors, drills and fans.

Each machine has a unique vibration signature, and deviations from this pattern can be a strong indicator of mechanical problems. The ability to monitor vibration in real-time allows for early intervention, preventing costly repairs and downtime.

Oil Analysis

By analyzing oil for contaminants, viscosity changes, and particle counts, technicians can pinpoint wear and tear in machine components. Chemical analysis of oil can also reveal overheating or chemical degradation, providing early warnings of issues that could lead to failure.

This technology is often used in heavy industries, such as energy production or oil drilling, where machinery components are subject to extreme operating conditions.

Current and Voltage Sensors

These sensors track electrical characteristics like overloads, short circuits, and failing components. In industries such as mining or energy, where electrical systems are critical, monitoring these parameters ensures safety and minimizes downtime caused by electrical failures.

For example, real-time analysis of electrical data in mining operations can help identify potential issues in equipment like excavators or conveyors, allowing operators to address problems before they cause equipment failure and disrupt production.

Predictive Maintenance and Satellite IoT

For remote operations, such as those found in mining or offshore environments, Satellite IoT becomes a crucial part of the Predictive Maintenance Program. When assets are located in areas with unreliable or no cellular connectivity, traditional IoT solutions relying on cellular networks may fail to transmit vital data. Satellite IoT solutions overcome this challenge by enabling real-time data transmission via satellite, ensuring that assets can be monitored regardless of their location or environment.

Beyond just sensor data collection, Satellite IoT can enable remote control of assets. If an asset is detected to be operating in an unsafe condition, it can be remotely shut down to prevent catastrophic damage or safety incidents. This combination of real-time monitoring and remote intervention significantly enhances worker safety and helps avert equipment breakdowns before they escalate into more serious issues.

Get in Touch

At Ground Control, we design and build Satellite IoT devices leveraging the Iridium global network, providing reliable real-time data transfer from anywhere on Earth. Our feature-rich IoT platform, Cloudloop, can monitor and analyse sensor data and offers a simplified and well-documented API to connect to your existing Predictive Maintenance and Asset Performance Management (APM) toolkits.

With over 20 years of experience, we can help you make the best choices based on your requirements.

As the world of satellite IoT connectivity rapidly evolves, selecting the right network for your remote application has never been more important — or more complex. Whether you’re deploying environmental monitoring devices, controlling unmanned systems, or tracking remote assets, understanding your options can save you significant time, money, and operational effort.

That’s why we created a comprehensive guide to help you navigate this dynamic landscape and make informed choices. The highlights are in this blog post; read the eBook to digest the in-depth version.

Read Free eBook

The Expanding Satellite IoT Landscape

In recent years, satellite networks have undergone a transformation. Established players have diversified their services, offering greater flexibility and more competitive pricing. At the same time, new satellite constellations are launching at a faster rate than ever, introducing innovative services and standards that promise even more possibilities for IoT applications.

This abundance of options is great news, but it also presents a challenge: with so many variables at play, how do you select the best network for your specific needs? That’s where our expertise comes in. Ground Control has spent over 20 years testing and integrating satellite networks to ensure optimal connectivity for our customers. We’ve distilled our knowledge into an easy-to-follow eBook that covers everything you need to consider.

Key Considerations for Choosing a Satellite Network

When evaluating satellite IoT networks, there are several critical questions to ask:

How data-intensive is your application? Understanding your data volume needs is crucial. For instance, message-based services like Iridium Messaging Transport (IMT) are ideal for low-volume, energy-efficient data transmission. On the other hand, IP-based services such as Iridium Certus 100 are better suited for high-data applications like real-time control or video streaming.
Where are your sensors located? Coverage matters. While some networks like Iridium offer truly global coverage, others may not reach polar regions or other remote areas. Additionally, factors like terrain and obstructions can affect the choice between Low Earth Orbit (LEO) and Geostationary (GEO) satellites.
Is your application stationary or mobile? Mobile applications often require LEO networks, as they don’t rely on precise antenna alignment. Conversely, stationary deployments with a clear line of sight to a GEO satellite may benefit from the stability and cost-effectiveness of GEO-based solutions.
How time-critical is your data? Applications requiring real-time data transmission will need well-established LEO networks with IP-based connections. For less time-sensitive use cases, store-and-forward technologies used by some newer LEO networks might be a cost-effective alternative.

Standards-Based vs. Proprietary Networks

One of the most exciting developments in satellite IoT is the emergence of standards-based technologies like LTE Cat 1 and NB-IoT over satellite. These allow a single modem to connect to both cellular and satellite networks, promising cost savings and supplier flexibility. However, these technologies are still in their infancy and come with trade-offs, such as higher power consumption or limited data volumes.

Where you have a combination of relatively high data volumes plus no mains power, proprietary networks offer optimized performance tailored to their specific satellite systems. For instance, message-based protocols like Iridium’s Short Burst Data (SBD) deliver efficient, low-power communication for small data packets, making them ideal for battery-powered IoT devices.

What You’ll Learn in the eBook

Our eBook, How to Choose the Right Satellite IoT Network, dives deeper into these topics and provides actionable insights, including:

A detailed comparison of leading satellite networks like Iridium, Viasat, Starlink, and Globalstar.
Real-world examples of how different networks excel in specific use cases.
A practical framework for evaluating networks based on coverage, latency, power efficiency, and mobility.
Insights into emerging technologies and how they may impact your future connectivity strategy.

By the end of this guide, you’ll have the tools you need to select a satellite IoT network that aligns with your technical and operational requirements.

Read Free eBook

Can we help with your remote IoT application?

We have decades of experience designing and building satellite IoT connectivity solutions, and work with multiple satellite networks to ensure our customers get the right service for their needs.

If you would like expert, impartial advice on your remote IoT application, please get in touch! Complete the form or email hello@groundcontrol.com. We will reply within one working day.

Iridium have just launched their latest satellite transceiver, the Iridium Certus 9704. In this post we’re going to explore how this module compares with other satellite IoT modems, the Iridium 9603 and Certus 9770. We’ll look at ideal use cases for the new transceiver, how to get the best out of the device, and how to get started.

What is the Iridium Certus 9704?

The 9704 is a small, lightweight and low power satellite IoT transceiver that connects to the globally available Iridium satellite constellation.

It leverages Iridium Messaging Transport (IMT), a message-based service which allows users to transmit data packets of up to 100 kB. What is IMT?

What Applications are Suited to the 9704?

The 9704 has been designed to consume very little power, so it’s ideal for remote, battery-powered applications. For example, telemetry from heavy machinery; SCADA readings from unmanned substations or infrastructure; aggregated gateway / hub data; data logger transmissions.

It can also be used for simple UxV commands; stop, start, return etc.

How Does the 9704 Differ from the 9603 Transceiver?

The 9704 module is 34% smaller than the 9603N modem: 31.5 x 42 x 3.8 mm vs. 31.5 x 29.6 x 8.1 mm, and 12 g vs. 11.4 g respectively*.

The 9704 also boasts an 83% reduction in idle power consumption compared to the 9603. The message size for the 9603 is considerably smaller compared to the 9704; 340 / 270 bytes (Short Burst Data) vs. 100 kB (Iridium Messaging Transport). The link speed is also doubled with the 9704; from 2.4 Kbps to 4.8 Kbps.

Applications best suited to the 9603 include asset tracking, environmental monitoring and fleet management; it remains the most cost-effective way to move very small volumes of data using the Iridium satellite constellation. But for many applications, IMT will be a more cost-effective means of transmitting IoT data.

View 9603-Based Products

How Does the 9704 Differ From the 9770 Transceiver?

The Iridium Certus 9770 modem is a more powerful device. It can send data over IMT, but also over IP, creating greater flexibility and making it more suitable for applications where real-time command and control is required – for example, piloting a drone BVLOS.

The 9770 sends data far more quickly; 22 / 88 Kbps vs the 9704’s 4.8 Kbps (Tx/Rx). But this comes with a greater power draw; the 9770 requires 3.5 W to transmit/receive, whereas the 9704 requires just 400 mW*.

The 9770 is also larger and heavier than the 9704; 140 x 60 x 16 mm and 185 g vs. 31.5 x 42 x 3.8 mm and 12 g respectively*.

The Certus 9770 can be used for voice communication, and the 9704 is data only.

Devices utilizing the 9770 transceiver are ideal for remote control of assets such as UAVs and USVs; or when it’s important that data is moved quickly, so any form of alerting mechanism such as remote security or systems failure alarms. They will also be the preferred choice of systems integrators who want the flexibility to switch between IP and message-based transmissions depending on the type of data being moved.

View 9770-Based Products

Which Devices Utilize the 9704 Transceiver?

At the time of writing, you can purchase a 9704 developer kit and build the 9704 transceiver into your enclosure. We are IMT and Iridium experts, having worked with the Iridium development team for decades, and we are here to help you get the best out of Iridium Messaging Transport.

We are prototyping two new devices to leverage the new technology; the RockBLOCK Pro, for IoT applications, and the as-yet-unchristened successor to the RockFLEET, which is our multi-purpose, all-weather tracking and IoT device.

What is Iridium Messaging Transport (IMT)?

Launched in late 2022, IMT is Iridium’s most recent satellite IoT service. It is message-based, which is the most cost-effective and power-economical way to communicate with satellite networks (vs. an IP connection which has a substantial overhead).

With a message-based service, you pay only for the data you choose to transmit, and only when it’s successfully transmitted. However, a drawback of message-based services is that the data has to be reformatted before it reaches your preferred destination; unlike IP-based communication, it isn’t a commonly utilized format.

We built Cloudloop Data to address this challenge. This delivers simplified store and forward IoT messaging between your devices and cloud-based services. Messages can be fanned to multiple endpoints, from cloud providers like Azure and AWS, to IoT dashboards including ThingsBoard and ThingSpeak. You also have the option to consume the decoded data in your own system, through delivery methods including email, MQTT and HTTP webhook.

How to Get Started With the Iridium Certus 9704

We encourage you to contact us to discuss your application; we are Iridium experts, and will provide you with impartial advice on the best airtime, service and hardware to best meet your needs.

We’re responsive, friendly and helpful, and we genuinely love helping people solve their remote connectivity problems, so please get in touch!

*Information on the 9704 is subject to change.

Get in Touch

To get in touch with our team of Iridium experts, please complete the form, email hello@groundcontrol.com, or call us on one of the below numbers.

We will respond to your message within one working day.

UK: +44 (0) 1452 751940

USA: +1.805.783.4600

Heavy industrial sectors have continued to push the boundaries of what is possible in some of the most remote and challenging locations on the planet. Industry 4.0 has been a transformative technological leap for the traditional industries of mining, agriculture, forestry and construction, bringing new monitoring and automation capabilities to the heavy equipment that these sectors rely on.

In remote mining, farming, forestry or construction sites, an equipment breakdown can cost thousands in downtime. For industries operating far from cellular coverage, ensuring machinery stays operational is a challenge that Satellite IoT is solving with real-time data and monitoring. In this blog, we’ll explore how IoT can enable the transformation of heavy machinery operations, tackling issues like maximizing cost of ownership, preventing downtime, and safety and environmental compliance.

Heavy Equipment Total Cost of Ownership (TCO)

Purchasing specialized heavy equipment is a significant investment, and in recent years those costs have been steadily climbing as manufacturers pass on their increased raw material and labor costs. The Capital Expenditure (CapEx) involved means that each machine must be operated effectively, efficiently and within agreed tolerance limits to reduce maintenance costs and prevent costly downtime.

The theft of heavy equipment is also commonplace, with over 11,000 incidents of construction theft reported annually in the US and an average average loss of $35,000 to $45,000 per machine. Theft also has a considerable impact on operational timescales, as well as increased costs to replace or lease equipment.

Worker Safety cost

Hazardous Work Environments

With heavy industry recognised as one of the most hazardous places to work (accounting for 63 per cent of all fatal occupational injuries) worksite safety requirements have, quite rightly, been improving on a global scale as Governments enforce a duty of care on industry operators.

However, it remains that despite these improvements, a diminishing workforce is entering these physically challenging industries based in remote locations. This has led to increased Operational Expenditure (OpEx) to attract high quality skilled candidates.

Environmental and Sustainability Targets

Heavy industry accounts for around a third of global energy consumption and emits a quarter of global Greenhouse Gas emissions. Pressures from Governments to hold businesses to account for their carbon emissions and environmental impacts particularly affect these industries.

To meet agreed environmental commitments, operations may need to invest in technology to analyse the worksite’s impact on the surrounding area and consider upgrading heavy machinery to meet emissions targets.

Operational Complexity

Keeping to contractual timescales on any large project involving heavy machinery is ultimately reliant on the equipment being reliable. Delays in specialist heavy equipment arriving on-site and unexpected breakdowns can lead to extensive project delays and wasted resources, all of which lead to an increased OpEx.

Without clearly-defined logistical operation data to coordinate fuel deliveries and material transport, an entire site could come to a standstill.

Connectivity Limitations

Mining, forestry, farming and construction operations often take place in remote locations with limited or no mobile or cable internet coverage. The cost of connecting fixed or cellular telco equipment or laying cables for site connectivity is often very expensive, especially when real-time communication is required for equipment operations or emergency protocols.

The return on investment for installing a dedicated network on a site which may only be operational for 10-15 years is often poor and can become a negative cost.

Six Innovations in Heavy Machinery Operations

Many of the issues facing industries using heavy machinery can be mitigated against by using technology, data and connectivity.

With satellite connectivity more reliable than cellular in remote locations and increasingly more competitively priced, the cost-effectiveness and profitability of mining, forestry, construction and agriculture operations can be significantly improved and many of the key issues facing the industry can be resolved.

1. Predictive Maintenance

Predictive maintenance is a data-driven approach to keeping heavy machinery operating at peak performance and efficiency. By continuously monitoring on-board sensors for feedback on tire wear, oil and fuel consumption, engine temperatures, hydraulic pressures, vibrations, stability and acceleration, machinery can be proactively inspected and maintained according to usage, rather than reactively when a breakdown occurs.

Satellite IoT devices can transmit real time data on machine usage and even enable a shutdown of equipment if thresholds are exceeded. By planning machine maintenance downtime, preventing failures that could lead to accidents, and monitoring machinery operatives driving behaviour, the operation expenditure of the site can be effectively managed and optimized.

The 2021 McKinsey & Company ‘The Internet of Things’ Report highlighted that in the construction sector, employing IoT applications can improve uptime by 30 to 50 percent and increase throughput by 1 to 5 percent.

An additional benefit of monitoring machinery usage is to provide a better return on the CapEx of the machinery when the equipment is sold at the end of the project.

2. Remote Monitoring

Remote monitoring of site personnel and equipment can enable the operational efficiency of worksites, as well as ensure the safety of all workers on-site. With satellite-connected asset trackers on equipment and team members, remote operations centres can use geo-fencing capabilities to keep personnel and heavy machinery apart using safety zone alerts. Should a team member stray into the path of an oncoming vehicle, both the individual and the driver can be alerted to the potential risk.

Satellite IoT enabled sensors can detect worksite ambient conditions to ensure staff and machinery are not exposed to extreme working temperatures, strong winds, excessive rainfall or poor air quality. By encouraging and demonstrating a commitment to site safety, labor recruitment can be improved.

Site operations can be further optimized through monitoring of raw material tanks and silos (e.g. concrete and chemical reagents), machinery fuel consumption, generator fuel levels and final product storage and collection (e.g. metal ores, timber, grain). By integrating satellite IoT sensors across the work site, logistics managers can ensure fuel and raw material deliveries and product collections are planned according to site requirements, reducing bottlenecks and improving operational efficiency.

According to McKinsey and Company, operators which have more than 50% of their vehicle fleet connected to the internet have 23% better financial performance than peers with less than 50% connected. Companies with more than 75% of their fleet connected have 51% better financial performance.

3. Telematics

Monitoring heavy equipment on-site is integral to operational performance, and can also ensure the worksite is remaining committed to its safety, sustainability and environmental goals.

Aside from monitoring onboard sensors for predictive and reactive maintenance, telematics can also improve driver behavior, which in turn can reduce fuel consumption and carbon emissions. Heavy industry equipment by its nature burns fossil fuels and emits greenhouse gases during operation, but there are opportunities to limit these effects.

In the construction industry alone, machinery idle time averages 36% which increases fuel consumption by up to 5%. The biggest operational opportunity for reducing the potential for idling is ensuring vehicles are dispatched to their collection or drop-off locations according to requirements rather than on a continuous cycle, thereby preventing fleet waiting times.

There is also driver behavior to consider, with some operators leaving machinery idling during their break periods. Using real-time telematics, Site Managers can address the machinery operator actions immediately and encourage them to turn the machine off when not in use.

Through these two simple actions it is possible to reduce fuel costs, decrease carbon emissions, limit noise pollution and improve worksite air quality. When industry profit margins are challenging, evidence has shown that operators who lag behind their peers in reducing downtime are losing future business, wasting time and money, and increasing their ecological impact on the environment.

4. Theft Prevention

Heavy equipment theft costs the USA construction and agricultural industry an estimated $300 million to $1 billion annually, and is especially prevalent during the National Holidays of Labor Day, Memorial Day, Independence Day and Thanksgiving when worksites are closed and machinery is left unattended.

Satellite-connected video surveillance can enable real-time monitoring and recording of remote worksites and storage areas to protect both staff and equipment from unauthorized access.

Remote Video Surveillance Heavy Equipment

Heavy equipment can be fitted with discreet satellite asset trackers which can alert the operations team when equipment has moved out of a geofenced area or the machinery is being operated outside of normal worksite hours. Satellite assets trackers are especially effective at tracking stolen heavy machinery as they can keep connected across borders, and in the case of the Iridium network anywhere on Earth. Improvement in asset tracking capabilities has led to an increase in machinery recovery rates from 5% to 20% in the last 15 years.

5. Machine Learning and AI

Incorporating AI and machine learning capabilities into the mining, forestry, agriculture and construction industry has the potential to transform how these sectors address the challenges of CapEx and OpEx, as well as their environmental impacts. By leveraging data-driven analysis, businesses can optimize workforce and heavy machinery productivity, identify opportunities for fuel savings and emission reduction, limit raw material wastage and improve final product quality and volumes. Insights from these analyses can be replicated across multiple work site locations and integrated into cost projections for future projects, driving efficiency and sustainability.

6. Autonomous and Remote Control Heavy Machinery

One of the most significant challenges facing the mining, agriculture, construction, and forestry industries is an aging workforce, with many skilled workers nearing retirement and fewer new recruits stepping into these roles. Technological advancements in developing and implementing autonomous and remote operation of heavy equipment are helping to manage labor shortages while enhancing productivity and safety.

Autonomous Haulage Systems (AHS) are already in use across large-scale mining operations, enabling unmanned dump trucks to optimize hauling cycles, improve payload accuracy, and increase operational efficiency. However, not all scenarios are suitable for full automation, which is where remote control solutions come into play.

In hazardous environmental conditions or working on difficult or sloping terrain, controlling heavy machinery via remote control allows operators to manage equipment from a safe distance nearby or within a central operations hub. This minimizes risks to personnel while maintaining operational efficiency.

Both autonomous and remote-controlled systems rely on a continuous flow of real-time data, including video feeds and telemetry data, to ensure precise operation and avoid collisions. Satellite connectivity provides reliable and seamless data exchanges in remote locations, enabling the integration of automation and remote operation of heavy machinery in complex environments.

Satellite IoT Solutions for Heavy Machinery Monitoring

Satellite IoT is supporting innovation within the heavy machinery industry, addressing critical challenges such as remote connectivity, safety, and operational efficiency. By leveraging real-time data through predictive maintenance, telematics and remote monitoring, businesses can reduce costs, improve productivity, and meet stringent environmental goals. As automation and AI continue to transform the sector, embracing satellite-enabled solutions is essential for staying competitive in an increasingly connected world.

Get in Touch

Contact us to discover how our satellite IoT solutions can drive efficiency and profitability for your heavy machinery fleet.

With 20 years of experience, we can help you make the best choices based on your requirements.

Please call us on us on +44 (0) 1452 751940 (Europe, Asia, Africa, Oceania) or +1.805.783.4600 (North and South America); email hello@groundcontrol.com, or complete the form.

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Can we help?

Securing IoT Data: Why Satellite Connectivity Matters

82%

say CNI organizations aren’t investing enough in cybersecurity

62%

would feel safer if CNI organizations had backup satellite connectivity

93%

of CNI organizations report an increase in cyber threats

Key Insights from the Report

1. The Growing Cybersecurity Threat to IoT Networks

2. Why Satellite IoT Offers a More Secure Alternative

3. How to Mitigate the Limitations of Satellite Data Security

4. Expert Insights from Leading Satellite Providers

Can we help level up data security for your organization?

What is Predictive Maintenance?

What is the Difference between Predictive and Preventive Maintenance?

Comparing the Two Approaches

Types of Predictive Maintenance

The Benefits of Predictive Maintenance

40%

Cost Savings

30-45%

Downtime Reduction

75%

Fewer Equipment Breakdowns

How to Implement Predictive Maintenance

1. Establish Baselines and Data Collection

2. Install IoT Sensors on Equipment

3. Data Integration and System Setup

4. Set Maintenance Thresholds and Automate Alerts

5. Select and Implement the Right Analytics Tools

6. Develop Predictive Models and Train the System

7. Integration with Existing Maintenance Systems

8. Monitor and Optimize the Program

Industrial Applications of Predictive Maintenance

Energy and Utilities

Railways and Transportation

Oil and Gas

Mining

Sensor Technologies in Predictive Maintenance

Infrared Thermography

Acoustic Monitoring

Vibration Analysis

Oil Analysis

Current and Voltage Sensors

Predictive Maintenance and Satellite IoT

Get in Touch

Overheating and
Thermal Shutdowns

Drop and
Impact Vulnerability