In the framework of maintenance optimization of multi-component systems, dynamic grouping has developed and becomes an interesting approach. However, most existing dynamic grouping models assume that the repair time is negligible. This assumption may be not always relevant and limits the application of these models in many real situations. The main objective of this paper is to develop a dynamic grouping model taking into account both preventive and corrective maintenance duration for complex structure systems. Analytical method is developed for the evaluation of total maintenance cost. This analytical method helps to overcome, when compared with simulation methods, the computational time problem which often is a big problem for the maintenance optimization of systems with a large number of components. A numerical example is presented to show how the proposed grouping approach can be used for the maintenance planning of a complex structure system containing 12 components. A link with the coastal highway route E39 project is also discussed.
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