The Impact of Corrosion on the Residual Lifespan of Crane Metal

Structures
Bakhtiyarli Elvin1,a, Safarli Ali2,b
1
Azerbaijan Technical University, Baku, Azerbaijan
a
[email protected]; [email protected]

Keywords: Lifting machines, metal structure, corrosion, diagnostics, residual lifespan, corrosion rate.

Abstract: This paper evaluates the impact of corrosion on the residual lifespan of lifting machines. It
outlines the key aspects of a calculation methodology used to assess their actual service life and
investigates necessary measures to extend their operational lifespan. Furthermore, the conditions for
inspecting cranes that have exceeded their normative service life are examined in accordance with
existing standards. The study also evaluates how corrosion affects the residual lifespan of cranes.

Introduction
In many industries, lifting machines are continuing to operate beyond their intended service life,
a situation that presents significant challenges. Replacement of these machines is often delayed due to
limited budgets and increased production demands that prioritize immediate operational needs over long-
term safety. Fortunately, many cranes were designed with high strength reserve coefficients, allowing
them to function longer than outlined in their technical documentation. However, this extended use raises
concerns about their reliability and safety as they age[1].
In current operational settings, one of the most pressing requirements is the ability to precisely identify
when technical inspections and maintenance are needed. Once a crane surpasses its normative service
life, it becomes critical to evaluate its remaining lifespan. This assessment allows operators to determine
whether extending the machine’s usage is feasible. Regular monitoring of a crane's condition is a key
factor in this decision-making process, requiring expert evaluations and compliance with both regulatory
and operational standards[2][3].
The condition of aging cranes varies significantly. While some machines completely lose their
functionality, others retain partial or full operational capacity. This variability underscores the
inefficiency of uniformly decommissioning all cranes that exceed their intended service life. Instead,
decisions about their continued use should rely on scientifically validated methods. For example, the
"Rules for the Design and Safe Operation of Lifting Cranes" mandate thorough technical diagnostics for
cranes that have exceeded their expected lifespan, alongside detailed calculations of their remaining
operational potential[4].
Traditionally, crane service life is measured in time units such as engine hours. However, this method
is increasingly viewed as insufficient for assessing the durability of metal structures. Research suggests
that evaluating service life based on operational cycles offers a more accurate reflection of the stresses
experienced by the equipment, particularly in high-demand environments[5].
Given that lifting cranes are classified as high-risk equipment, precise diagnostics are essential to
identifying potential failures before they occur. Proactive safety measures, informed by residual lifespan
assessments, can significantly reduce the likelihood of accidents. While achieving absolute precision in
lifespan calculations is unrealistic, reliable estimation methods provide actionable insights. Alarmingly,
recent statistics show that 85% of cranes in operation have surpassed their intended lifespan, and 20%
are in critical condition. Furthermore, 85% of crane-related accidents are attributed to operational
failures, highlighting the need for rigorous evaluation processes[6][7].
 By calculating the residual lifespan of cranes, organizations can take the necessary steps to extend
their service life responsibly. These steps often involve repairing damaged structures and replacing worn
components, a process that continues to attract the attention of global experts seeking to improve safety
and reliability in crane operations[8][9].

Residual Lifespan Assessment

To evaluate the residual lifespan of cranes that have exceeded their normative service life according
to existing standards, the following conditions must be assessed:
- The presence of multiple fatigue cracks, especially in previously repaired nodes.
- Corrosion of load-bearing elements in the metal structures of lifting machines.
- Deformations caused by accidental local loads not accounted for in the design, such as the impact of
the load or grab bucket on the crane’s metal structure, or collisions between moving parts of two cranes.
Operational experience with lifting machines indicates that one of the most common defects is
corrosion damage to metal structural elements. However, insufficient attention has been given to this
issue, resulting in a lack of well-established standards for permissible levels of corrosion damage.
Studying the dynamics of various corrosion defects and their impact on the reliability of metal structural
elements is a key task in evaluating residual lifespan. This challenge can be addressed by developing
adequate models to analyze the effects of corrosion defects and damaged elements in metal structures
(Fig.1).

Fig 1. Image of corrosion crane components

Corrosion Diagnostics
It is important to note that during diagnostics, the condition of metal structures is generally assessed
by determining the presence of cracks, the extent and depth of corrosion damage, and the overall state of
the protective lacquer coating, which acts as the primary barrier against corrosion processes [4, 5, 6].
Corrosion is a more significant issue for machines and equipment exposed to environmental
interactions. Its relevance is particularly pronounced in facilities utilizing outdated metal structures,
machinery, tools, and transportation equipment. Corrosion processes vary in nature depending on their
causes. However, they share a common characteristic: they result from the interaction between metals
and their environment (physical-chemical or chemical). This process severely affects the metal structures
of lifting machines, leading to their degradation. Corrosion can silently compromise the structural
strength, causing severe accidents and emergencies, including human casualties. The restoration of
corroded structures and the replacement of equipment due to corrosion are costly for the owners.
 During the inspection of crane metal structures, the primary task is to identify and evaluate corrosion
damage. Corrosion may result in general or localized destruction. General corrosion uniformly reduces
the cross-sectional area of an element, diminishing its load-bearing capacity. Conversely, localized
corrosion, while involving less metal loss, is more dangerous as it creates stress concentration points.
Corrosion is typically measured by its penetration rate into the metal (mm/year). The corrosion rate is
influenced by environmental factors (humidity, aggressiveness, temperature), the properties of the metal,
and other structural considerations.

Types of Corrosion in Crane Metal Structures

Cranes' metal structures may experience various types of corrosion, including general, localized,
atmospheric, contact, stress-crack, and selective corrosion. The most critical threat to crane metal
structures arises from localized forms such as pitting and ulcer corrosion, which manifest as cavities,
voids, and other depressions on the metal surface, creating multiple stress concentrators [7].
Cranes' metal structures are typically made of low-carbon and low-alloy steels. This composition
allows for the hypothesis that both pitting and ulcer corrosion types may occur. As the damage deepens
in the material, these corrosion types converge into pitting corrosion (Fig.2), making its progression
particularly critical.

Fig 2. Pitting damage to metal structures

Corrosion Rate Calculation

To evaluate the corrosion process, one of the key quantitative parameters is the corrosion rate. This
parameter can be expressed in terms of mass loss as follows:

m
vm 
S t
where:
- m : change in the metal's mass,
- S : surface area,
- t : time [8, 9].
The annual corrosion rate in terms of depth can be calculated using the formula:
 8,76  vm
vП 

where:
- 8.76 is the conversion factor to account for hours in a year (24 hours × 365 days = 8760 hours),
-  : density of the metal structure material in q/sm3.
The volumetric corrosion rate can also be expressed as:
V
vV 
S t
(Additional volumetric formula as referenced in [8]).
When the damage is unevenly distributed, it is not practical to determine the corrosion rate using mass
or depth indicators. In such cases, the rate of pit corrosion is determined based on the maximum depth
of the pits. Granular corrosion and crack formation require quantitative evaluation using indirect
indicators, such as strength loss:

 mk   m
v 
 mk

where:
-  mk : strength limit before corrosion,
-  m : strength limit after corrosion.
Numerous approaches have been developed to determine the corrosion rate. In practice, the
methodology primarily relies on the average corrosion rate to provide a conservative estimate [10].

Preventive Strategies to Mitigate Corrosion

Mitigating corrosion in crane metal structures is a crucial aspect of extending their operational lifespan
while ensuring safety and efficiency. A combination of advanced materials, protective coatings, and
systematic maintenance practices can significantly reduce the impact of corrosion. This section outlines
some of the most effective preventive strategies.
1. Application of Protective Coatings
Protective coatings are the first line of defense against environmental factors that contribute to
corrosion. Advanced solutions such as epoxy-based and polyurethane coatings offer high durability,
resisting moisture and chemical exposure effectively. Nanotechnology has also introduced
nanocomposite coatings, which significantly improve wear and corrosion resistance due to their superior
bonding properties and increased barrier efficiency[11][12].
2. Cathodic Protection Systems
Cathodic protection is a widely adopted method to combat corrosion, particularly in marine and
industrial environments. This method works by making the metal structure a cathode within an
electrochemical cell, thereby preventing oxidation. Impressed current cathodic protection (ICCP)
systems have proven to be particularly effective for large-scale applications, providing long-term
durability even in highly aggressive environments[13][14].
3. Regular Maintenance and Inspections
Routine maintenance and inspections are essential for early detection and remediation of corrosion.
Current best practices emphasize the use of IoT-enabled sensors to monitor key parameters such as
humidity, temperature, and stress levels in real time. Predictive maintenance approaches, informed by
data analytics, allow for timely interventions, reducing unplanned downtime and operational
risks[15][16].
4. Material Selection and Design Optimization
The selection of materials plays a pivotal role in mitigating corrosion. Corrosion-resistant alloys, such
as stainless steel and aluminum-magnesium alloys, are increasingly being used in crane structures.
Design optimization is equally important; features such as closed structural profiles and rounded edges
minimize water and debris accumulation, reducing the risk of localized corrosion[17][18].
5. Environmental Control
Environmental control measures are highly effective but often overlooked. Climate-controlled storage
areas for cranes, dehumidification systems, and chemical containment protocols can significantly reduce
the risk of corrosion. Additionally, anti-corrosive greases and lubricants applied to crane components
provide an added layer of protection[19][20].
By adopting these strategies, organizations can extend the service life of cranes, improve safety, and
reduce overall maintenance costs. The integration of preventive measures with advanced diagnostic tools
offers a comprehensive solution to the challenges posed by corrosion in crane metal structures.
Case Studies and Real-World Examples
The practical implications of corrosion management in crane metal structures can be best understood
through real-world case studies. These examples illustrate the critical importance of timely interventions
and the effectiveness of various mitigation strategies.
Case Study 1: Extending the Lifespan of Port Cranes through Coating Technology
A major shipping port in Southeast Asia faced significant corrosion damage in its fleet of gantry
cranes, primarily due to high humidity and salt exposure. By implementing a multi-layer epoxy coating
system specifically designed for marine environments, the port managed to restore the structural integrity
of the cranes. The project involved surface preparation through sandblasting, followed by the application
of a primer and two topcoats. This solution extended the operational lifespan of the cranes by over 15
years and significantly reduced maintenance costs[21].
Case Study 2: Failure of an Industrial Bridge Crane Due to Localized Corrosion
In a North American manufacturing facility, an industrial bridge crane experienced catastrophic
failure after a stress fracture in its load-bearing element went unnoticed. Post-incident analysis revealed
that pitting corrosion had formed deep cavities in the metal structure, which acted as stress concentrators.
The lack of regular inspections and reliance on outdated diagnostic methods contributed to the oversight.
This incident highlighted the importance of implementing modern inspection techniques, such as
ultrasonic testing, to detect subsurface corrosion early[14][12].
Case Study 3: Implementation of IoT Sensors in Mining Cranes
In a South American mining operation, cranes exposed to extreme temperatures and abrasive dust
frequently required expensive repairs. The company adopted IoT-enabled sensors to monitor
environmental conditions and structural stress in real time. This proactive approach allowed for the
detection of corrosion hotspots and stress anomalies before they escalated into critical failures. Over
three years, the use of these sensors reduced crane downtime by 30% and maintenance costs by 25%.
The success of this project demonstrated the potential of predictive maintenance in harsh operational
environments[15].
Lessons Learned
These case studies emphasize several key points:
1. Proactive Maintenance Saves Costs: Timely interventions, such as applying advanced coatings
or using predictive technologies, can significantly reduce long-term expenses.
2. Advanced Diagnostics Prevent Failures: Modern tools, including ultrasonic testing and IoT
sensors, offer crucial insights that traditional methods often miss.
3. Environment-Specific Strategies Matter: Solutions tailored to the operational environment,
such as marine or mining settings, are critical for effective corrosion management.
By examining these real-world examples, it becomes evident that integrating preventive strategies with
cutting-edge technology is essential for ensuring the longevity and reliability of crane structures.

Conclusion
Corrosion poses a significant challenge to the operational efficiency and safety of crane metal
structures, particularly as many of these machines operate beyond their normative service life. This paper
has underscored the importance of addressing corrosion through accurate diagnostics, preventive
strategies, and advanced technological interventions. By integrating methods such as non-destructive
testing, predictive maintenance, and protective coatings, organizations can extend the lifespan of cranes,
reduce operational risks, and minimize maintenance costs.
The case studies presented highlight the tangible benefits of proactive corrosion management, from
extending the service life of port cranes to preventing catastrophic failures in industrial settings. These
examples demonstrate that adopting tailored solutions based on environmental conditions and leveraging
emerging technologies like IoT sensors are pivotal in combating corrosion effectively.
Future efforts should prioritize the development of global standards for permissible corrosion levels
and the adoption of innovative materials, such as self-healing alloys, to further enhance durability.
Additionally, incorporating AI-driven tools into diagnostic processes offers the potential to revolutionize
how crane structures are monitored and maintained.
Ultimately, the findings and strategies discussed in this paper serve as a foundation for ensuring the
reliability and safety of crane operations while addressing the economic and environmental challenges
posed by corrosion. By fostering a culture of continuous improvement and innovation, the industry can
navigate the complexities of corrosion management and secure sustainable operations for the future.

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