SHM is a very important process in terms of the safety and durability of infrastructure. Traditional SHM often faces problems detecting minor structural defects and handling large datasets. Therefore, certain more advanced approaches are called for. The paper discussed the applications of AI and ML algorithms, such as CatBoost and the African Vultures Optimization Algorithm, for such challenges. The research is based on a unique dataset of 8,541 rows and diverse features, developing a predictive framework that enhances crack detection and forecast capabilities. The approach mainly deals with heterogeneous data using the CatBoost algorithm, given its capability for high-accuracy predictions, while AVOA optimizes feature selection, reduces the computational cost, and guarantees no loss in model performance. This methodology has resulted in a significant enhancement of the prediction accuracy, which states the importance of AI-ML integration in SHM. The key results demonstrate the effectiveness of the model in detecting structural anomalies and crack propagation to enable proactive maintenance strategies. This study’s contributions have gone toward advancing SHM with scalable and efficient AI-ML frameworks, enabling real-time monitoring for better infrastructure management. Such development might have a transforming potential to cut down on maintenance costs and enhance operational safety, thus further encouraging sustainable infrastructure systems.