Heavy Duty Casters: How to Choose Casters for Heavy Loads

Machines, moulds and pallets moved around factories and warehouses are heavy. At these loads the wrong caster flattens quickly, damages the floor or makes the cart impossible to push. Three things decide the choice of a heavy duty caster: load per caster, floor and how often it moves.

Heavy duty casters (up to 1,000 kg / 2,200 lb per caster)

• Polyurethane casters: Polyurethane tread on a cast iron or polyamide centre. High capacity and floor friendly at the same time: low push force, quiet, non-marking. Often the first choice for in-plant transport. 55–200 mm (2–8 in), 80–1,000 kg (175–2,200 lb).
• Polyamide (nylon) casters: Hard and very wear resistant; unaffected by oil, chemicals and moisture. Very low rolling resistance on smooth floors, but being hard they do not absorb vibration or noise. 55–200 mm (2–8 in), 130–800 kg (285–1,760 lb).
• Cast iron casters: The toughest type against impact, heat and swarf. Hard on floors, so used in workshops, foundries and outdoor areas. 55–200 mm (2–8 in), 140–900 kg (310–1,985 lb).
• Spring-loaded casters: A suspension unit in the housing absorbs shocks on uneven floors and protects sensitive equipment and loads from vibration. 150–200 mm (6–8 in), 400–1,000 kg (880–2,200 lb).
• High temperature casters: Heat-resistant polyamide wheels for oven trolleys and hot process areas.

Extra heavy duty casters (up to 3,500 kg / 7,700 lb per caster)

At loads measured in tonnes, the housing matters as much as the wheel:

• Fabricated steel casters: Heavy plate steel housing with polyurethane wheels on roller bearings. 150–200 mm (6–8 in), 400–1,000 kg (880–2,200 lb).
• Cast housing casters: The housing is cast as well; for heavy machinery and mould transport. 150–300 mm (6–12 in), 700–1,600 kg (1,540–3,530 lb).
• Twin wheel casters: Share the load over two wheels and reduce pressure on the floor. 200–350 mm (8–14 in), 2,000–3,500 kg (4,400–7,700 lb).

Points to watch with heavy loads

1. Leave a safety margin. Divide the total weight not by the number of casters but by one less (by 3 on a four-caster cart). See the worked examples in our caster load capacity guide.
2. Bigger wheels push easier. Under the same load a 200 mm wheel rolls over thresholds and floor joints far more easily than a 125 mm wheel.
3. Bearings are a must. Under heavy, frequent movement, ball or roller bearings cut push force and extend service life.
4. Brakes and steering. A heavy cart must have brakes; on long runs a layout of 2 rigid + 2 swivel casters keeps it on line.
5. Don't forget replacement wheels. If the housing is sound, replacing the worn wheel is enough. See our wheels.

For jobs whose size or capacity falls outside our catalogue we offer custom manufacturing. Request a quote →