New bh will have 6 mm side plates and 8 mm top and bottom. How did you determine grade of steel on the boom?
S355 is the only thing Cat uses... We modify booms and sticks for Cat and Hitachi importers, high reach demolition, long reach dredging, thats why we get the info when we need it for a modification.
Even the big mining excavators use just S355... If it has to last, you need more steel to lower the strain. High strength steel is only useful for static, or limited design life applications because the welds have the same, or worse, fatigue life before they start cracking, than S355...
HIAB truck mount cranes are Domex 700, but when you use those as a construction hoist crane instead of a truck loading crane, it will be cracked all over within 1.5 years because it will see the number of load cycles in 1.5 year which a truck mounted loading crane (used to self load a transportation truck as intended, not as a cheap alternative for a tele crane) sees in 15 years.
In civil engineering, the same fatigue life (or max strain) is used for S355 as well as the most exotic high strength steel. I contacted our steel supplier, and some research centers, and i found only some German research with hard, conclusive data about the differences in fatigue life between S690 and S355 base material (S690 base material only has a better fatigue life in low cycle, high strain fatigue) and in welded S690 and welded S355 (The S355 weld had a slightly better fatigue life)