Integrated Technical Condition Assessment of Aging Port Handling Equipment for Service Life Extension

The operation of port handling equipment that has been in long-term service under marine conditions is accompanied by intensive cyclic loading, corrosion, fatigue damage, deformation, and mechanical wear. The integration of engineering diagnostics, condition-based maintenance, structural assessment, and residual service-life evaluation provides a reliable basis for decision-making regarding repair, strengthening, modernization, controlled operation, and service-life extension. Purpose. To investigate modern European approaches to maintenance management of aging port handling equipment and assess their applicability to extending crane service life under long-term marine conditions. Method. The study considers the principal degradation mechanisms identified during technical inspections, including corrosion, fatigue cracking, permanent deformation, and wear of structural and mechanical components. The obtained data are used to assess technical condition, structural integrity, operational safety, and residual service life. The application of Condition-Based Maintenance and Structural Health Monitoring is also considered. Results. The analysis confirms that corrosion, fatigue, deformation, and wear are the main factors limiting the service life of aging port cranes. An integrated maintenance approach improves maintenance planning, reduces operational risks, and supports economically justified decisions on repair, modernization, and service-life extension. Scientific novelty. An integrated engineering framework combining technical inspection, structural assessment, residual-life evaluation, condition-based maintenance, and digital monitoring is proposed. Practical importance. The approach can be applied by port authorities, maintenance organizations, classification societies, and engineering companies to improve maintenance planning, enhance safety, reduce unexpected failures and maintenance costs, and extend the service life of existing port handling equipment.