To Build or Not to Build? Extending the Lifespan of Your Fleet with Structural Monitoring

The decision to invest in new vessels or continue operating existing assets is one of the most significant strategic challenges shipowners face today. With steel prices soaring and operational costs under constant scrutiny, the long-term financial and operational implications of each choice must be carefully weighed. However, one factor is often overlooked in these discussions: the role of Structural Health Monitoring (SHM) in extending a ship’s lifespan. By embedding SHM into new builds from the outset, or retrofitting existing vessels, shipowners can optimize their investments, manage risk, and ultimately ensure that every ship delivers maximum value over its entire operational life.

With SHM, shipowners must rely on conservative safety margins in ship design, often opting for thicker steel to account for potential structural uncertainties over time. This approach, while accepted by most, is costly. The reality is that structural integrity is not a fixed equation – it evolves over decades as a ship endures varying loads, stresses, and environmental conditions. Without real-time or at least periodically updated data, a cautious approach must be taken, which could lead to retiring ships prematurely or overspending on maintenance. SHM changes this equation, shifting decision-making from guesswork to precision.

For existing fleets, SHM enables operators to monitor real-time stress and fatigue levels, allowing them to move from rigid maintenance schedules to condition-based maintenance strategies. Instead of inspecting or repairing components based on a predetermined calendar, shipowners can act only when the data indicates intervention is necessary. This not only extends operational life but also reduces maintenance costs and minimizes downtime. Continuous monitoring provides an early warning system for fatigue, corrosion, and cracking – problems that, if left undetected, can lead to costly emergency repairs or even structural failure. By identifying these issues early, shipowners gain the flexibility to plan ahead, optimizing dry-docking schedules and reducing unplanned disruptions.

While SHM clearly benefits existing vessels, integrating it into new builds from day one provides significant lifecycle advantages. By embedding SHM sensors during construction, shipyards and shipowners gain a comprehensive dataset that tracks the vessel’s structural health from the moment it enters service. This data-driven approach ensures that maintenance decisions are based on real-world operating conditions rather than theoretical assumptions. Over time, this can lead to significant cost savings, not just in maintenance but also in design itself.

Considering again the question of steel thickness for newbuild designs. Ships are overbuilt to accommodate uncertainty, but with SHM, naval architects can take a more data-informed approach at the time and for future designs. If monitoring shows that structural loads are well within acceptable limits, further vessels in a series can be designed with optimized steel thickness – reducing material costs without compromising safety. This principle has already been demonstrated in large-scale fleet projects such as the Qatargas LNG carrier program, where early SHM data helped validate structural integrity and informed smarter design choices in subsequent vessels.

Moreover, as the regulatory landscape continues to evolve, having SHM in place ensures compliance with emerging standards. While class societies have introduced hull monitoring

notations, the industry is moving towards a future where real-time structural health data could play a central role in certification and safety assurance. By investing in SHM from the start of a newbuild project, shipowners not only future-proof their fleets but also gain a competitive edge by demonstrating a proactive approach to asset management.

Ultimately, the question is not just whether to build or not to build, it’s how to build smarter. With SHM, shipowners can extend the service life of their current assets while ensuring that new builds are designed for longevity and cost-efficiency from the start. As operational costs rise and environmental pressures intensify, data-driven decision-making will be the key to sustaining profitability and reliability in the maritime industry.