The Different Types of Heavy-Duty Castors

How do you ensure the smooth and efficient movement of heavy loads in industrial, commercial, or logistical settings? Heavy-duty castors are designed to bear substantial weight and withstand rigorous use, making them essential for applications where mobility and load handling are critical. In this guide, we’ll help you better understand heavy-duty castors, covering:

• The Importance of Choosing the Right Heavy-Duty Castor
• The Basic Components of Heavy-Duty Castors
• Fixed vs. Swivel Heavy-Duty Castors: What's the Difference?
• Types of Heavy-Duty Castors: Wheel, Load Capacity, and Floor Surface
• Maintenance and Inspection of Heavy-Duty Castors

The Importance of Choosing the Right Heavy-Duty Castor

Generally, castor wheels are considered heavy duty when they can handle a minimum load capacity of 140 kg – 230 kg per castor. It’s important to get this right for your application. In fact, the consequences of using the wrong heavy-duty castors should not be taken lightly. You need to carefully assess the specific requirements of your application, or else you’re looking at potentially serious problems, such as:

Reduced Load Capacity

If the chosen castors have a lower load capacity than the actual weight of the load, they may fail or wear out prematurely. Overloading the castors can lead to excessive stress on the wheels, bearings, and overall structure, resulting in premature failure and potential damage to the load or surrounding equipment.

Getting it right: By selecting the right heavy-duty castors with an appropriate load capacity, you can ensure that they safely carry the weight of your intended load. 

Increased Maintenance and Downtime

Inadequate castors may require more frequent maintenance or replacement, leading to increased downtime and interruptions in operations. This can result in reduced productivity, increased costs, and delays in meeting project deadlines.

Getting it right: Choosing heavy-duty castor wheels made from durable materials and featuring robust construction ensures long-term reliability and minimises the risk of breakdowns or failures during operation.

Poor Manoeuvrability and Handling

Incorrect castor selection can hinder the smooth movement and manoeuvrability of heavy loads. Inadequate castors may have limited swivel capabilities, lack proper wheel diameter, or offer insufficient traction, making it difficult to navigate tight spaces or uneven surfaces. This can result in strain on operators, reduced efficiency, and increased risk of accidents or damage to goods and equipment.

Getting it right: Selecting heavy-duty castors with appropriate features based on the application's requirements ensures easy manoeuvring, reducing operator strain and optimising productivity.

Floor Damage and Safety Hazards

Choosing castors with inappropriate wheel materials or designs can result in floor damage, such as scratches, marks, or even structural issues. This not only compromises the aesthetics and functionality of the space but also poses safety risks for personnel and equipment. Damaged or uneven floors can lead to tripping hazards and cause instability during load movement.

Getting it right: Choosing heavy-duty castors with suitable wheel materials and designs can help mitigate floor damage by providing proper weight distribution, cushioning, and floor surface compatibility.

Increased Noise and Vibration

Incorrect castors can generate excessive noise and vibration during operation, which can be disruptive, uncomfortable, and potentially harmful to both operators and nearby equipment. Excessive noise can also affect the overall working environment, leading to decreased productivity and potential compliance issues with noise regulations.

Getting it right: Selecting castors with features like shock-absorbing properties, smooth rolling mechanisms, and vibration-damping materials contributes to a quieter and more comfortable working environment.

Compromised Safety

Choosing the wrong heavy-duty castors can compromise safety in the workplace. Inadequate castors may not provide secure mounting, reliable braking mechanisms, or stability required for safe load handling. This increases the risk of accidents, including load slippage, tip-overs, or injuries to personnel.

Getting it right: The appropriate heavy-duty castors provide stability, secure mounting, and reliable braking mechanisms. The result: they prevent accidents, maintain control, and protect both operators and loads from potential harm.

Costly Replacements

If the chosen heavy-duty castors fail or do not meet the intended requirements, it may necessitate costly replacements or retrofits. This not only incurs additional expenses but also results in the loss of the initial investment made in choosing the wrong heavy-duty castors.

Getting it right: Appropriate heavy-duty castor wheels for your needs saves money in the long run. 

The Basic Components of Heavy-Duty Castors

With so many different types of castors, components vary. But there are some basics they all share. Using a heavy-duty swivel castor as our example, you can expect to find these fundamental components: 

Top plate: Mounts underneath the heavy equipment that you’re placing on castors.

Wheel: Rolls along floor, enabling the heavy equipment to move.

Fork: Support structure that connects the top plate to the swivel section. Both sides of the fork have a hole drilled in its lower end. The wheel’s axle is inserted into these two holes, connecting the wheel to the bottom end of the fork.

Ball bearing swivel: Allows the castor to rotate or swivel freely, enabling multidirectional movement. 

Note, if the fork attaches directly to the top plate, then these are rigid castors, also known as heavy-duty fixed castors. 

Axel: A metal rod that passes through the centre of the wheel and allows it to rotate. 

Fixed vs. Swivel Heavy-Duty Castors: What's the Difference?

Fixed and swivel heavy-duty castors are two common types of castors that differ in their design and functionality. Here's a breakdown of the differences between them:

Heavy-duty fixed castors:

1. Directionality: Designed to move in a straight line only. They do not rotate or swivel, providing stability and straight-line movement.
2. Mounting: Typically mounted to the equipment or object in a fixed position using a top, or mounting, plate. They are secured in place and do not allow for rotation or swivelling.
3. Stability: Provides excellent stability and support, as they are fixed in position and do not allow for rotation. Commonly used in applications where stability and load-bearing capacity are crucial, such as heavy machinery or equipment that requires minimal movement.

Heavy-duty swivel castors:

1. Manoeuvrability: A heavy-duty swivel castor offers 360-degree rotation and swivelling capabilities. It allows for multidirectional movement, making them highly manoeuvrable and flexible for easy navigation around corners, tight spaces, or uneven surfaces. Commonly used in applications where frequent changes in direction or movement are required.
2. Mounting: Swivel castors typically have a swivel section that enables rotation and swivelling. They are mounted to the equipment or object using a mounting plate or other fastening mechanisms, allowing free rotation around the vertical axis.

Types of Heavy-Duty Castors: Wheel, Load Capacity, and Floor Surface

A range of heavy-duty castors are available, each designed with specific wheel materials, load capacities, and floor surface compatibility. You’ll want to ensure your application does not exceed the castors’ load capacity. 

Wheel material is also important. Heavy-duty castors often come in:

• Rubber: Rubber tyres offer good traction, shock absorption, and are gentle on floors. Provides quiet operation. Blue elastic rubber is a popular choice. 
• Polyurethane: Durable with high load-bearing capacity, and can operate on both indoor and outdoor surfaces. Popular in industrial and heavy-duty applications.
• Phenolic: Excellent load-bearing capacity and durability. They provide high impact resistance and can withstand exposure to chemicals and extreme temperatures.
• Nylon: Nylon wheels are known for their strength, toughness, and resistance to chemicals. Suitable for heavy-duty use on smooth or rough surfaces.
• Cast Iron: Cast iron wheels offer high load capacity and durability, particularly in rugged environments. Never use these on wood floors. 

Finally, think about floor surface compatibility to prevent floor damage and ensure smooth movement:

• Hard Floors: Rubber, nylon or polyurethane wheels are generally suitable for hard surfaces like concrete, tile, hardwood, and coated floors, as they provide traction without causing damage.
• Soft Floors: For soft or delicate floors such as carpets, low-friction wheels like nylon or polyurethane are preferred to minimise the risk of indentations or marks.
• Uneven or Rough Surfaces: Wheels with larger diameters or those with tread patterns are typically better suited for uneven or rough surfaces to ensure smoother movement and load distribution.

Heavy-duty industrial castors

Heavy-duty industrial castors are typically used in automotive, engineering, and manufacturing. Ultimately designed to bear heavy loads, these castors are usually used on industrial equipment such as dolly carts, storage racks, tow lines, maintenance equipment, platform trucks and more. Additional applications where they apply are also given below. These can also be used as heavy-duty furniture castors and heavy-duty workbench castors. 

Examples of heavy-duty industrial castors include:

Castor wheels, heavy duty: additional applications

Heavy-duty castors aren’t limited to industrial applications. You’ll find them wherever load capacities are demanding. 
 

Heavy-duty adjustable castors

These heavy-duty adjustable castors are designed to provide the ability to level and stabilise equipment or structures on uneven surfaces. 
 

Maintenance and Inspection of Heavy-Duty Castors

Proper maintenance and regular inspection are vital for preserving the optimal condition of heavy-duty castors and ensuring a safe working environment. Here are some essential practices to consider:

1. Cleanliness: Routinely remove debris and dirt from the castors using non-abrasive methods. Avoid using harsh chemicals that may cause damage.
2. Lubrication: Adhere to the manufacturer's recommendations for lubricating the castor bearings. Proper lubrication reduces friction, extends bearing life, and ensures smooth rolling. Avoid excessive lubrication that can attract dust and debris.
3. Damage Check: Thoroughly inspect the castors for any signs of damage, including cracks, wear, or fractures. Pay close attention to the wheels, bearings, top plates, and swivel mechanisms. Promptly replace any damaged components to prevent further issues.
4. Load Assessment: Regularly assess the load capacity of your heavy-duty castors to avoid overloading. Compare the load rating with the actual weight being transported. Overloading can lead to premature wear, decreased performance, and safety risks.
5. Brake Functionality: If equipped with brakes, regularly inspect and test them to ensure proper functionality. The brakes should engage and release smoothly, securely holding the equipment or load as needed.
6. Floor Protection: Monitor the interaction between the castor wheels and the floor surface to prevent damage. Employ floor protectors or consider alternative castor types to minimise the risk of scratches or marks.

Download free CADs and try before you buy

Free CADs are available for most solutions, which you can download. You can also request free samples to ensure the product you’ve chosen is exactly what you need. 

If you’re not even sure you should use castors, check out our guide, Should You Choose Glides or Castors?

You should also check out our range of castor wheels. 

Whatever your requirements, you can depend on fast despatch. Request your free samples or download free CADs now.

Questions?

Email us at sales@essentracomponents.co.uk or speak to one of our experts for further information on the ideal solution for your application 0345 528 0474.