Experimental measurement methods used in operational mode provide valuable information about the behavior of mechanical parts of equipment that cannot be determined in advance by analytical calculations or numerical modeling. The strain gauge method, which is often used to investigate the stresses in the load-bearing members of steel structures under operational conditions, was used. The advantage is the fast and accurate acquisition of stress values at critical locations selected based on analytical computations or numerical modeling. In the present paper, the residual operating life of two main girders of a bridge crane was assessed by an analytical-experimental approach. The input parameters for the assessment were obtained from the evaluated stress time records and using the Rainflow Counting method. Experimental measurements identified an almost 50% decrease in the residual life of one of the girders. It was caused by non-compliance with the technological procedures for the regular replacement of the rails, where the rail was welded to the top flange on one of the girders. Considering realistic operating conditions, predicting the effect of welded rail on fatigue damage accumulation, performed by other than experimental procedures, is almost impossible for such complex structures. This paper not only documents the importance of experimental measurements but also highlights the significance of selecting measurement locations with consideration of the current technical state of the structure.

The subject of the research presented in this article is the dimensional optimisation of the box structure of the main girder for overhead cranes, with the aim to reduce the main girder’s own weight. Described are the applied optimisation methods and also the problems arising during the optimisation process. Loss of shape stability is analysed in more detail, as well as the methods determined for a constructional proposal of the girder cross-section. The developed optimisation procedure is a combination of the calculations, performed in the MS Excel environment, with the simulation of a parametrically modelled girder realised using Dassault Systèmes SolidWorks software v. 2023. Using the example of optimisation of an overhead crane girder with a lifting capacity of 50 tons, the effectiveness of the proposed optimisation procedure is declared, where the existing overhead crane box girder is compared with the optimised cross-section of the box girder.