Rework network to 6-tier Clos topology with individual switch entities

Replace aggregate network health stats with a full 6-tier Clos topology
(ToR → T1 → T2 → T3 → T4 → T5) where every switch is an individually
tracked entity with uplinks, repair pipelines, and failure cascades.

Key mechanics:
- Bottleneck bandwidth model (min along path) affects FLOPS and satisfaction
- Rackdown on full disconnect → racks re-enter testing pipeline on recovery
- Binomial failure sampling per tier, dirty-flag cascade optimization
- Flat switch registry for performance at scale
- Three new research nodes: network-redundancy, fast-repair, hot-standby

Co-Authored-By: Claude Opus 4.6 <noreply@anthropic.com>

apps/web/src/pages/InfrastructurePage.tsx

@@ -14,7 +14,8 @@ import {
   formatMoney, formatNumber, formatPercent,
   LOCATION_CONFIGS, DC_TIER_CONFIGS, RACK_SKU_CONFIGS,
   CAMPUS_TIER_COSTS, CLUSTER_COST_CONFIG, FIRST_CAMPUS_BUILD_TICKS,
-  networkSlotsRequired, maxComputeRacks,
+  estimateNetworkSlots, maxComputeRacks,
+  SWITCH_TIER_CONFIGS,
   DC_UPGRADE_COST_FRACTION, DC_UPGRADE_INCREMENT,
 } from '@ai-tycoon/shared';
 import type {
@@ -26,12 +27,14 @@ const ERA_ORDER: Era[] = ['startup', 'scaleup', 'bigtech', 'agi'];
 
 const STAGE_LABELS: Record<PipelineStage, string> = {
   ordered: 'Ordered', manufacturing: 'Mfg', receiving: 'Recv',
-  installation: 'Install', testing: 'Testing', repair: 'Repair', decommission: 'Decom',
+  installation: 'Install', testing: 'Testing', repair: 'Repair',
+  'network-down': 'Net Down', decommission: 'Decom',
 };
 
 const STAGE_COLORS: Record<PipelineStage, string> = {
   ordered: 'bg-surface-600', manufacturing: 'bg-blue-500', receiving: 'bg-cyan-500',
-  installation: 'bg-violet-500', testing: 'bg-amber-500', repair: 'bg-danger', decommission: 'bg-surface-500',
+  installation: 'bg-violet-500', testing: 'bg-amber-500', repair: 'bg-danger',
+  'network-down': 'bg-red-600', decommission: 'bg-surface-500',
 };
 
 // ─── Shared Components ──────────────────────────────────────────
@@ -112,7 +115,7 @@ function Breadcrumb({ nav }: { nav: InfraNav }) {
 
 function DeploymentProgressBar({ dc }: { dc: DataCenter }) {
   const tierConfig = DC_TIER_CONFIGS[dc.tier];
-  const maxCompute = maxComputeRacks(tierConfig.rackSlots);
+  const maxCompute = maxComputeRacks(tierConfig.rackSlots, dc.tier);
   const pipelineRacks = dc.deploymentCohorts.filter(c => c.stage !== 'decommission').reduce((s, c) => s + c.count, 0);
   const totalTarget = dc.computeRacksOnline + pipelineRacks;
   const pct = totalTarget > 0 ? (dc.computeRacksOnline / totalTarget) * 100 : 0;
@@ -157,23 +160,27 @@ function CohortStageBreakdown({ cohorts }: { cohorts: DeploymentCohort[] }) {
 }
 
 function NetworkHealthIndicator({ dc }: { dc: DataCenter }) {
-  const nh = dc.networkHealth;
-  if (nh.tier1Required === 0) return null;
+  const ns = dc.networkSummary;
+  if (ns.switchIds.length === 0) return null;
 
-  const allHealthy = nh.tier1Healthy === nh.tier1Required
-    && nh.tier2Healthy === nh.tier2Required
-    && nh.tier3Healthy === nh.tier3Required;
+  const hasDisconnected = ns.racksDisconnected > 0;
+  const hasDegraded = ns.racksDegraded > 0;
+  const coreDown = (ns.healthyByTier?.t3 ?? 0) < (ns.totalByTier?.t3 ?? 0);
 
-  const color = nh.tier3Healthy < nh.tier3Required ? 'text-danger'
-    : !allHealthy ? 'text-amber-400'
+  const color = coreDown ? 'text-danger'
+    : hasDisconnected ? 'text-danger'
+    : hasDegraded ? 'text-amber-400'
     : 'text-green-400';
 
+  const bwPct = Math.round(ns.averageBandwidth * 100);
+
   return (
     <div className={`flex items-center gap-1 text-xs ${color}`}>
       <Network size={12} />
       <span>
-        {nh.tier3Healthy < nh.tier3Required ? 'Core Down'
-          : !allHealthy ? `${nh.racksDisconnected} disconnected`
+        {coreDown ? 'Core Down'
+          : hasDisconnected ? `${ns.racksDisconnected} disconnected`
+          : hasDegraded ? `${bwPct}% bandwidth`
           : 'Healthy'}
       </span>
     </div>
@@ -661,7 +668,7 @@ function FillAllDCsModal({ campus, money, era, research, onConfirm, onClose }: {
       const { qty, cost } = computeFillForDC(dc, selectedSku, remaining);
       if (qty === 0) {
         const tierConfig = DC_TIER_CONFIGS[dc.tier];
-        const maxCompute = maxComputeRacks(tierConfig.rackSlots);
+        const maxCompute = maxComputeRacks(tierConfig.rackSlots, dc.tier);
         const pipelineCount = dc.deploymentCohorts.filter(c => c.stage !== 'decommission').reduce((sum, c) => sum + c.count, 0);
         const isFull = maxCompute - (dc.computeRacksOnline + pipelineCount) <= 0;
         return { dc, qty: 0, cost: 0, reason: isFull ? 'Already full' : 'No budget' };
@@ -929,7 +936,7 @@ function CampusDetailView({ clusterId, campusId }: { clusterId: string; campusId
   const hasRetrofitQueue = !!campus.retrofitQueue;
 
   const fillableDCs = operationalDCs.filter(dc => {
-    const maxCompute = maxComputeRacks(tierConfig.rackSlots);
+    const maxCompute = maxComputeRacks(tierConfig.rackSlots, dc.tier);
     const pipelineCount = dc.deploymentCohorts.filter(c => c.stage !== 'decommission').reduce((sum, c) => sum + c.count, 0);
     return maxCompute - (dc.computeRacksOnline + pipelineCount) > 0;
   });
@@ -1124,12 +1131,12 @@ function DataCenterDetailView({ clusterId, campusId, datacenterId }: {
   if (!dc || !cluster) return <div className="text-surface-400">Data center not found.</div>;
 
   const tierConfig = DC_TIER_CONFIGS[dc.tier];
-  const maxCompute = maxComputeRacks(tierConfig.rackSlots);
+  const maxCompute = maxComputeRacks(tierConfig.rackSlots, dc.tier);
   const pipelineCount = dc.deploymentCohorts.filter(c => c.stage !== 'decommission').reduce((s, c) => s + c.count, 0);
   const existingCompute = dc.computeRacksOnline + pipelineCount;
   const availableSlots = maxCompute - existingCompute;
   const sku = dc.rackSkuId ? RACK_SKU_CONFIGS[dc.rackSkuId] : null;
-  const netSlots = networkSlotsRequired(existingCompute);
+  const netSlots = estimateNetworkSlots(existingCompute, dc.tier);
 
   const availableSkus = Object.values(RACK_SKU_CONFIGS).filter(s => {
     if (ERA_ORDER.indexOf(era) < ERA_ORDER.indexOf(s.era)) return false;
@@ -1257,7 +1264,7 @@ function DataCenterDetailView({ clusterId, campusId, datacenterId }: {
                   {(() => {
                     const skuToUse = dc.rackSkuId ?? selectedSku!;
                     const skuConfig = RACK_SKU_CONFIGS[skuToUse];
-                    const newNetSlots = networkSlotsRequired(existingCompute + deployQty);
+                    const newNetSlots = estimateNetworkSlots(existingCompute + deployQty, dc.tier);
                     const addedNet = newNetSlots - netSlots;
                     const totalCost = skuConfig.baseCost * deployQty;
                     return (
@@ -1358,24 +1365,51 @@ function DataCenterDetailView({ clusterId, campusId, datacenterId }: {
                 <p className="text-sm text-surface-400">No racks online. Deploy racks to see network topology.</p>
               ) : (
                 <div className="space-y-3">
-                  {[
-                    { label: 'Tier-1 (ToR)', required: dc.networkHealth.tier1Required, healthy: dc.networkHealth.tier1Healthy, desc: `1 per ${24} compute racks` },
-                    { label: 'Tier-2 (Aggr)', required: dc.networkHealth.tier2Required, healthy: dc.networkHealth.tier2Healthy, desc: `1 per ${6} Tier-1 switches` },
-                    { label: 'Tier-3 (Core)', required: dc.networkHealth.tier3Required, healthy: dc.networkHealth.tier3Healthy, desc: 'Redundant pair' },
-                  ].map(tier => (
-                    <div key={tier.label} className="flex items-center justify-between p-3 border border-surface-600 rounded-lg">
-                      <div>
-                        <div className="font-medium text-sm">{tier.label}</div>
-                        <div className="text-xs text-surface-400">{tier.desc}</div>
-                      </div>
-                      <div className={`text-sm font-mono ${tier.healthy < tier.required ? 'text-danger' : 'text-green-400'}`}>
-                        {tier.healthy} / {tier.required}
-                      </div>
+                  {/* Bandwidth gauge */}
+                  <div className="p-3 border border-surface-600 rounded-lg">
+                    <div className="flex items-center justify-between mb-1">
+                      <span className="text-sm font-medium">Bandwidth</span>
+                      <span className={`text-sm font-mono ${dc.networkSummary.averageBandwidth < 0.8 ? 'text-warning' : dc.networkSummary.averageBandwidth < 0.5 ? 'text-danger' : 'text-green-400'}`}>
+                        {formatPercent(dc.networkSummary.averageBandwidth)}
+                      </span>
                     </div>
-                  ))}
-                  {dc.networkHealth.racksDisconnected > 0 && (
+                    <div className="w-full bg-surface-900 rounded-full h-2">
+                      <div
+                        className={`h-2 rounded-full transition-all ${dc.networkSummary.averageBandwidth >= 0.8 ? 'bg-green-500' : dc.networkSummary.averageBandwidth >= 0.5 ? 'bg-yellow-500' : 'bg-red-500'}`}
+                        style={{ width: `${dc.networkSummary.averageBandwidth * 100}%` }}
+                      />
+                    </div>
+                    <div className="flex justify-between mt-1 text-xs text-surface-500">
+                      <span>Effective FLOPS: {formatPercent(dc.networkSummary.effectiveFlopsFraction)}</span>
+                      <span>{dc.networkSummary.racksDegraded} degraded</span>
+                    </div>
+                  </div>
+
+                  {/* Per-tier switch health */}
+                  {(['tor', 't1', 't2', 't3'] as const).map(tier => {
+                    const total = dc.networkSummary.totalByTier[tier] ?? 0;
+                    if (total === 0) return null;
+                    const healthy = dc.networkSummary.healthyByTier[tier] ?? 0;
+                    const failed = total - healthy;
+                    const config = SWITCH_TIER_CONFIGS[tier];
+                    return (
+                      <div key={tier} className="flex items-center justify-between p-3 border border-surface-600 rounded-lg">
+                        <div>
+                          <div className="font-medium text-sm">{config.name}</div>
+                          <div className="text-xs text-surface-400">
+                            {tier === 'tor' ? '1 per rack (embedded)' : `Fan-out ${config.fanOut}, ${config.uplinkCount} uplinks`}
+                          </div>
+                        </div>
+                        <div className={`text-sm font-mono ${failed > 0 ? 'text-danger' : 'text-green-400'}`}>
+                          {healthy} / {total}
+                        </div>
+                      </div>
+                    );
+                  })}
+
+                  {dc.networkSummary.racksDisconnected > 0 && (
                     <div className="text-sm text-danger flex items-center gap-2 p-2">
-                      <Activity size={14} /> {dc.networkHealth.racksDisconnected} compute racks disconnected due to network failures
+                      <Activity size={14} /> {dc.networkSummary.racksDisconnected} compute racks disconnected due to network failures
                     </div>
                   )}
                 </div>

apps/web/src/store/index.ts

@@ -9,7 +9,7 @@ import type {
   Cluster, Campus, DataCenter, DCTier, RackSkuId, TrainingJob,
   ActiveResearch, OwnedDataset, LocationId,
   DeploymentCohort, PipelineStage,
-  NetworkHealthState, CampusRetrofitQueue,
+  CampusRetrofitQueue,
 } from '@ai-tycoon/shared';
 import type { FundingRoundType, OverloadPolicy, TuningPreset, ModelTuning } from '@ai-tycoon/shared';
 import {
@@ -25,9 +25,12 @@ import {
   FUNDING_ROUNDS,
   OPEN_SOURCE_REPUTATION_BOOST,
   LOCATION_CONFIGS,
-  networkSlotsRequired, maxComputeRacks,
+  estimateNetworkSlots, maxComputeRacks,
   uuid,
 } from '@ai-tycoon/shared';
+import {
+  emptyDCNetworkSummary, emptyCampusNetworkSummary, emptyClusterNetworkSummary,
+} from '@ai-tycoon/game-engine';
 import { INITIAL_RIVALS } from '@ai-tycoon/game-engine';
 
 export type ActivePage = 'dashboard' | 'infrastructure' | 'research' | 'models'
@@ -57,8 +60,14 @@ export interface GameNotification {
   read: boolean;
 }
 
-function emptyNetworkHealth(): NetworkHealthState {
-  return { tier1Required: 0, tier1Healthy: 0, tier2Required: 0, tier2Healthy: 0, tier3Required: 0, tier3Healthy: 0, racksDisconnected: 0 };
+function emptyDC(): Pick<DataCenter, 'networkSummary' | 'effectiveComputeRacks' | 'usedSlots' | 'usedPowerKW' | 'energyCostPerTick' | 'maintenanceCostPerTick' | 'currentUptime'> {
+  return {
+    networkSummary: emptyDCNetworkSummary(),
+    effectiveComputeRacks: 0,
+    usedSlots: 0, usedPowerKW: 0,
+    energyCostPerTick: 0, maintenanceCostPerTick: 0,
+    currentUptime: 1,
+  };
 }
 
 interface Actions {
@@ -189,7 +198,7 @@ export function computeFillForDC(
 
   const sku = RACK_SKU_CONFIGS[skuId];
   const tierConfig = DC_TIER_CONFIGS[dc.tier];
-  const maxCompute = maxComputeRacks(tierConfig.rackSlots);
+  const maxCompute = maxComputeRacks(tierConfig.rackSlots, dc.tier);
   const pipelineCount = dc.deploymentCohorts.filter(c => c.stage !== 'decommission').reduce((sum, c) => sum + c.count, 0);
   const existingCompute = dc.computeRacksOnline + pipelineCount;
   const available = maxCompute - existingCompute;
@@ -319,6 +328,7 @@ export const useGameStore = create<Store>()(
           status: isFirst ? 'operational' : 'constructing',
           constructionProgress: isFirst ? 0 : 0,
           constructionTotal: isFirst ? 0 : CLUSTER_COST_CONFIG.buildTimeTicks,
+          networkSummary: emptyClusterNetworkSummary(),
         };
 
         return {
@@ -358,6 +368,7 @@ export const useGameStore = create<Store>()(
           constructionProgress: 0,
           constructionTotal: buildTime,
           retrofitQueue: null,
+          networkSummary: emptyCampusNetworkSummary(),
         };
 
         return {
@@ -398,17 +409,11 @@ export const useGameStore = create<Store>()(
           rackSkuId: null,
           computeRacksOnline: 0,
           computeRacksFailed: 0,
-          networkHealth: emptyNetworkHealth(),
+          ...emptyDC(),
           deploymentCohorts: [],
           retrofitState: null,
           coolingLevel: 0,
           redundancyLevel: 0,
-          effectiveComputeRacks: 0,
-          usedSlots: 0,
-          usedPowerKW: 0,
-          energyCostPerTick: 0,
-          maintenanceCostPerTick: 0,
-          currentUptime: 1,
         };
 
         return {
@@ -437,14 +442,14 @@ export const useGameStore = create<Store>()(
         if (sku.requiredResearch && !s.research.completedResearch.includes(sku.requiredResearch)) return s;
 
         const tierConfig = DC_TIER_CONFIGS[dc.tier];
-        const maxCompute = maxComputeRacks(tierConfig.rackSlots);
+        const maxCompute = maxComputeRacks(tierConfig.rackSlots, dc.tier);
         const pipelineCount = dc.deploymentCohorts.filter(c => c.stage !== 'decommission').reduce((sum, c) => sum + c.count, 0);
         const existingCompute = dc.computeRacksOnline + pipelineCount;
         const available = maxCompute - existingCompute;
         const actualQty = Math.min(quantity, available);
         if (actualQty <= 0) return s;
 
-        const totalNetSlots = networkSlotsRequired(existingCompute + actualQty);
+        const totalNetSlots = estimateNetworkSlots(existingCompute + actualQty, dc.tier);
         const totalSlotsNeeded = existingCompute + actualQty + totalNetSlots;
         if (totalSlotsNeeded > tierConfig.rackSlots) return s;
 
@@ -484,7 +489,7 @@ export const useGameStore = create<Store>()(
 
         const dc = found.dc;
         const tierConfig = DC_TIER_CONFIGS[dc.tier];
-        const maxCompute = maxComputeRacks(tierConfig.rackSlots);
+        const maxCompute = maxComputeRacks(tierConfig.rackSlots, dc.tier);
         const pipelineCount = dc.deploymentCohorts.filter(c => c.stage !== 'decommission').reduce((sum, c) => sum + c.count, 0);
         const existingCompute = dc.computeRacksOnline + pipelineCount;
         const available = maxCompute - existingCompute;
@@ -522,17 +527,11 @@ export const useGameStore = create<Store>()(
             rackSkuId: null,
             computeRacksOnline: 0,
             computeRacksFailed: 0,
-            networkHealth: emptyNetworkHealth(),
+            ...emptyDC(),
             deploymentCohorts: [],
             retrofitState: null,
             coolingLevel: 0,
             redundancyLevel: 0,
-            effectiveComputeRacks: 0,
-            usedSlots: 0,
-            usedPowerKW: 0,
-            energyCostPerTick: 0,
-            maintenanceCostPerTick: 0,
-            currentUptime: 1,
           });
         }