1. Choose the Right Caster Weight Rating to Move Heavy Equipment
The first thing you need to look for is the load rating of the caster, which is called the weight capacity or load capacity. When a caster is rated for a given weight, that weight is based on the maximum recommended load per caster or wheel when operating intermittently (no faster than 3 mph) on a smooth surface, without shock loads or adverse environmental conditions.
Casters come in three weight ranges. Light-duty casters can handle up to 500 pounds. Medium-duty casters can handle 501 to 2,000 pounds. Heavy-duty casters can handle over 2,000 pounds.
Remember that caster ratings are based on the load capacity of each caster (whether it is a swivel or rigid caster), not the load capacity of the entire set of casters. Therefore, before purchasing heavy-duty casters, determine the load capacity required for each caster. Do this by adding the weight of the heavy equipment to the weight of the cart, truck, or platform to which the casters will be mounted. Then add another 33% of this weight as a safety margin. Then divide the total weight by the number of casters on your cart, truck, or platform. The resulting number is the weight rating you must choose for each caster on your cart.
Remember, if you choose a caster that is not appropriate for the weight you are moving, the caster could fail (and your heavy equipment could collide with a worker), or your workers could be injured from overexertion because a lower-rated caster would make the weight harder to push.
2. Choose casters with a large enough width and diameter to move heavy equipment
All else being equal, casters with large wheels are easier to move than casters with small wheels. Large wheels are also stronger and can carry heavier loads and weight. Casters come in diameters from 1 inch to 25 inches. Try to buy casters with a diameter of at least 8 inches.
Heavy loads also require wider wheels. Casters come in wheel widths from ½ inch all the way up to 8 inches. Try to choose casters with a wheel width of at least 3 inches.
3. Choose the right caster hardness to move heavy equipment
The wheels on casters used to move heavy equipment are made from a variety of materials, including cast iron, ductile iron, phenolic, nylon, and polyurethane. Make sure you choose the right wheel material for your application.
For example, casters made from phenolic and other hard materials can collect staples, metal particles, and other floor debris that can become embedded in the wheel's tread. This debris can accumulate to the point where the wheels begin to groove the floor, leading to costly repairs.
The heavy-duty casters that are least likely to accumulate debris are made from durable polyurethane. The tread on these casters is soft enough to keep debris out (it bounces off). The wheels won't mar or mark, helping to reduce the time and money spent on floor care.
4. Equip casters with extended swivel leads to move heavy equipment
Heavy loads are harder to push, pull, and move than light loads because they have high rolling resistance. This can lead to lower back injuries and physical overexertion-the leading cause of workplace injuries.
The main reason for high rolling resistance on casters is the length of the swivel lead. The swivel lead (also called swivel offset) is the distance from the vertical centerline of the swivel portion of the caster to the vertical centerline of the wheel. Casters without or with standard swivel leads are harder to push, pull, and maneuver than casters with extended swivel leads. The heavier the load, the more you need an extended swivel lead on the caster.
5. Beware of Cheap Kingpins for Moving Heavy Equipment
Even casters designed to move heavy equipment can fail prematurely. In most cases, the primary cause of failure is the kingpin. The kingpin is a rivet, threaded stud, or bolt with a nut that holds the swivel caster's mounting plate and fork assembly together.
The caster kingpin is the most expensive part on the caster, the most expensive to replace, and the highest total cost of ownership. So, before you buy a set of heavy equipment moving casters, beware of cheap kingpins. Look for casters with a high-quality mechanism, such as one with a forged kingpin.
6. Consider low-maintenance (or maintenance-free) casters for moving heavy equipment
Some heavy equipment moving casters require time-consuming lubrication on a regular basis via Zerk accessories to prevent sticking. Or they are designed with an open raceway, which causes debris to accumulate in the upper bearing, damaging the caster and requiring regular repairs.
When buying heavy equipment moving casters, look for units that have a lubrication-free caster mechanism that is designed to naturally keep debris out of the raceway. These maintenance-free casters are more durable and perform better than traditional casters. This means less downtime and more productivity for you.
7. Buy the Right Number and Type of Casters to Move Heavy Equipment
Another thing to consider when choosing heavy equipment moving casters is that you buy enough casters and that you buy enough of the right type of casters. There are basically two types of casters: swivel casters and rigid casters. As the name implies, swivel casters can rotate 360 degrees. Rigid casters, on the other hand, are fixed and can only move in one direction.
Typically, an industrial cart or platform cart comes with four casters. Two swivel casters in the front allow for easy mobility, and two rigid casters in the back allow for directional control. But if you want to move heavy equipment, increase the number of casters to at least six. Place a swivel caster at each of the four corners and a rigid caster halfway between the two longest sides.
8. Use caster brakes to move heavy equipment
The heavier the load, the more dangerous it is if it loses control. So consider purchasing heavy-duty casters with brakes that lock the wheels in place when stationary to prevent the load from moving unattended.