METODOLOGIA PARA PRORROGAÇÃO DA VIDA ÚTIL EM PONTES ROLANTES

INTEGRAÇÃO ENTRE MODELAGEM COMPUTACIONAL E VALIDAÇÃO METROLÓGICA COM ANÁLISE DE INCERTEZA

Authors

DOI:

https://doi.org/10.69609/1516-2893.2026.v32.n3.a4304

Keywords:

Remaining Service Life, Overhead Cranes, ISO 12482, Measurement Uncertainty, Finite Element Method

Abstract

ABSTRACT:

Critical asset management in heavy industries requires strategies that balance operational safety and capital cost optimization (CAPEX). This paper presents a structured methodology for evaluating and extending the service life of overhead cranes that have reached the statistical limit of design cycles, as recommended by NBR 8400 and ISO 12482 standards. The approach is based on the integration of reverse engineering for recalculating the design report, numerical simulation via Finite Element Method (FEM) to identify critical regions under alternating stresses, and experimental validation through three-dimensional elastic deflection measurements. The core contribution of this research lies in the quantification of measurement uncertainty, ensuring that the validation of the computational model is quantitatively sound. Results demonstrate, through a case study on a 50-year-old operating equipment, that monitoring the Design Working Period (DWP) allows for the extension of safe performance, preventing the premature disposal of structurally sound assets.

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Author Biographies

Caio Camargo Caltabiano, Universidade de Taubaté

A professional with technical and higher education in Mechanical Engineering, specializing in Industrial Production Management (MBA UNESP) and currently pursuing a Master's degree in Mechanical Engineering at the University of Taubaté (UNITAU). Possesses solid experience in industrial engineering and maintenance, with a distinguished career in large multinational companies such as TENARIS CONFAB, TERNIUM, and DUPONT. Throughout their career, they have developed competencies in mechanical, hydraulic, and automation project management, cost center management, leadership of multidisciplinary teams, maintenance planning and control (SAP-PM/MM), as well as the implementation of new projects and optimization of performance indicators (MTTR, MTBF). They work with failure analysis methodologies such as RCA and FMEA, and in the development of technical and operational procedures, and as an instructor at TENARIS University and Colegio Técnico Tableau. They have international experience in Europe and Latin America, with experience in complex and demanding industrial environments. Currently works as a Maintenance Engineering Specialist at TENARIS. Seeks opportunities in academia, with an interest in contributing to the training of new mechanical engineering professionals, integrating practical experience with teaching and applied research.

Fernando Silva de Araújo Porto, Universidade de Taubaté

Holds a degree in Mechanical Engineering from the São Paulo State University "Júlio de Mesquita Filho" (1988), a master's degree in Mechanical Engineering from the São Paulo State University "Júlio de Mesquita Filho" (1996), and a doctorate in Materials Engineering from the Lorena School of Engineering, EEL USP (2003). He is a master maintenance engineer. He has experience in industrial maintenance and applied statistics in production, mainly working on the following topics: reliability, component lifespan, and mechanical maintenance. He has twice been awarded the Brazilian Mining and Metallurgical Industry Excellence Award, in 2009 and 2012. He was a Collaborating Professor at the University of Taubaté from 2015 to 2017. He is an Assistant Professor II, working since 2015 in the Aeronautical Engineering, Mechanical Engineering, Mechatronics Engineering, and Mechanical Production Engineering courses, among others. He coordinates research and technological innovation projects, such as 'Breaking Barriers' (stratospheric probes) and the Bajuta Team (Baja SAE). He worked as a Mechanical Engineer in the Physical Infrastructure Sector of the University Hospital of the Federal University of São Carlos. Temporary contract, through a Selection Process, Notice No. 677, of November 20, 2020 - HU-UFSCAR - EBSERH, being responsible for the mechanical maintenance of the hospital, including elevator systems, hydraulics, heating systems, air conditioning, exhaust, maintenance with locksmithing, joinery and carpentry services, and monitoring of works. He is the author of the books 'Stress Analysis in Industrial Pipelines' (LTC) and 'Thermodynamic Properties of Water'. He develops applied research in Aerodynamics, System Reliability, Discrete Event Simulation and Logistics, and atmospheric data analysis via LIDAR.

References

REFERÊNCIAS

ALBERTAZZI GONÇALVES JR, A.; SOUSA, A. R. de. Fundamentos de metrologia científica e industrial. 2. ed. Barueri: Manole, 2018.

ABNT - ASSOCIAÇÃO BRASILEIRA DE NORMAS TÉCNICAS. NBR 8400: Equipamentos de elevação e movimentação de carga - Regras para cálculo das estruturas. Rio de Janeiro: ABNT, 1984.

BIPM et al. JCGM 100:2008: Evaluation of measurement data - Guide to the expression of uncertainty in measurement (GUM). 1. ed. Sèvres: JCGM, 2008.

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CMAA - CRANE MANUFACTURERS ASSOCIATION OF AMERICA. CMAA Specification No. 70: Specifications for Top Running Bridge & Gantry Type Multiple Girder Electric Overhead Traveling Cranes. Charlotte: CMAA, 2020.

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GAO, X.; WANG, Z. Fatigue life assessment of crane structures based on real-world load spectra and ISO 12482. International Journal of Fatigue, Oxford, v. 170, p. 107511, 2023.

ISO - INTERNATIONAL ORGANIZATION FOR STANDARDIZATION. ISO 12482: Cranes - Monitoring for crane design working period. Genebra: ISO, 2014.

KOSER, K.; SAVKOVIC, M.; BULATOVIC, R. Determination of remaining working life of overhead cranes with box girders using finite element modeling. Engineering Structures, Oxford, v. 250, p. 113456, 2022.

MÜLLER, H.; MEIER, T. Large-scale dimensional metrology for structural health monitoring using laser trackers: an uncertainty approach. Measurement, Londres, v. 190, p. 110753, 2022.

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ZHAO, Y. et al. Digital twin-driven structural integrity assessment of aging heavy-duty overhead cranes. Engineering Failure Analysis, Oxford, v. 145, p. 107023, 2023.

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Published

2026-09-30

How to Cite

Camargo Caltabiano, C., & Silva de Araújo Porto, F. (2026). METODOLOGIA PARA PRORROGAÇÃO DA VIDA ÚTIL EM PONTES ROLANTES: INTEGRAÇÃO ENTRE MODELAGEM COMPUTACIONAL E VALIDAÇÃO METROLÓGICA COM ANÁLISE DE INCERTEZA. Journal of Exact Sciences, 32(3). https://doi.org/10.69609/1516-2893.2026.v32.n3.a4304

Issue

Vol. 32 No. 3 (2026)

Section

Articles

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Copyright (c) 2026 Caio Camargo Caltabiano, Fernando Silva de Araújo Porto

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