• Calculated stresses in Demag CC2000 track plate exceeds the permissible stresses. • Chemical composition of Demag CC2000 track plate do not meet specifications. • Microstructure of G22NiMoCr5-6 is tempered-martensitic structure. • High carbon content in G22NiMoCr5-6 affects impact energy. A repetitive failure of crawler track plate made of G22NiMoCr5-6 of heavy-duty crane is observed to be occurring with an average rate of one track plate fractured every 100 working hours, presenting a great problem that may impose hazard on personnel and raising direct and indirect costs required for maintenance, spare parts, and downtime costs. The objective of this research is to investigate the cause of track plate failure. An experimental investigation is carried out including chemical composition, tensile test, impact toughness, hardness test, and metallographic observation along with fractography analysis. Also, working stresses are defined by applying the finite element method. Based on the results of the experimental and computational analysis, the fracture of track plate made of G22NiMoCr5-6 predominantly resulted from deficiency in the track plate geometry design which increases stress concentration within the fracture region, in addition, slight deviation of material properties compared to those prescribed by the standard may have played a role in exacerbating the problem. [ABSTRACT FROM AUTHOR]