Global Material Handling System Integrators

Caster Types and Applications


Learn about Caster and Wheel Types and Applications

Caster and wheel equipment are manufactured for a variety of applications. Learn more as we break down the differences in durability and design,


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Caster Types



A rigid Caster has a rigid yoke and wheel assembly which permits only straight-line movement.



A swivel caster has a swivel yoke and wheel assembly that will allow rotation of 360 degrees, which permits movement in any direction.



A locking caster is an assembly that can be locked in place by some sort of mechanic device.

Heavy Duty Casters

Heavy Duty Casters are built to handle the stress of high capacities and rugged treatment, no matter what the intended application is. The rating of a caster is determined by the needs of the application. A heavy duty caster would have to hold a mere 100 lbs. per caster. For something industrial, a heavy duty caster might hold up to 10,000 lbs or more, and able to handle shock loading.

Heavy Duty caster wheels treads are selected based not only by capacity, but floor surface, expected temperatures, and need for ease of movement.  Wheel bearing selections are chosen by taking in factors such as handling of lateral stress, extreme temperatures, and higher rolling speeds.

Heavy duty casters also have various options for brakes. Many models feature 4-position swivel lock notches on the lower raceway, enabling fixed direction rolling.  Grease fittings are inserted into swivel raceways and wheel mounts ensuring ease of maintenance on most models.

Medium Duty Casters

Medium duty casters are engineered for loads from 500 to 1,250 lbs. in applications including hotel luggage carts, food service equipment, hospital beds, laundry carts, scaffolding, waste disposal trucks and pharmaceutical equipment. There are a variety of brake options and scaffolding casters which feature a total lock brake to positively secure wheels and swivel.

Stainless Steel Casters for Medical and Food Grade Applications

Stainless steel casters are often required in medical and food grade applications.  It’s important to note that the term "stainless steel caster" pertains to the connection, fork, and axle assemblies, and does not necessarily refer to the wheel.  There are a wide range of wheel options that can be selected depending upon the requirements of the application.

Some common uses of stainless steel casters include installations on food service carts, machinery dollies, parts bins, pharmaceutical trays and clean room equipment.

Stainless steel casters can be ordered with specific options for brakes and locks to meet your needs. Different bearing options can be used depending on your application. Stainless casters can also be made to fit specific load heights.

Conductive Casters for ESD Applications

The presence of ESD (electrostatic discharge) in the environments where the manufacture, construction and assembly of microprocessors, circuit boards, computers and sensitive electronic equipment takes place is a significant problem. Damage caused by ESD in the environments requiring the minimization of ESD include clean rooms, surgical suites and other medical environments, and where combustible gases are present.

;How does a typical ESD event occur? As those casters repeatedly move across the floor, they generate an electrical charge. When the worker comes in contact with the cart, that charge, in the form of ESD, will harmlessly travel into the worker’s body (human beings are excellent conductors of electricity). The next time the worker touches an ESD-sensitive component, such as a computer chip, the resulting ESD discharging can damage the chip.

There is no single method of dealing with ESD a series of safeguard strategies should be incorporated into the workplace environment where ESD is a factor. These strategies usually include charge prevention, grounding, shielding, neutralization and education.

Conductive or Dissipative Casters are important, but often overlooked, part of an overall system of protection against ESD.  Our team of experts is ready to assist you with selecting the correct conductive caster for your ESD application.

Dual Wheel Casters

The larger footprint of a dual wheel caster enhances stability and spreads the load over a larger floor area. The differential action inherent in all swivel dual wheel designs minimizes the effort required to change directions, providing ergonomic relief. Dual wheel casters offer the highest possible capacity at the lowest overall height. To achieve the greatest carrying capacity possible, forged steel wheels may be utilized. When floor protection is desired, a polyurethane tire should be considered. While the carrying capacity is reduced with the polyurethane tire, very high capacities are still achievable.
Dual Wheel Caster Features

  • Hot-Forged Steel Construction
  • 50,000 lbs Max. Capacity
  • Enhanced Stability

Dual wheel casters are excellent for tow lines, industrial platform trucks, rugged industrial functions and other severe abusive applications.
Dual Wheel Casters can be designed around either a kingpinless swivel section or an integral king pin style caster. These casters feature thick sectioned legs that are welded to a unique skirt design for greater strength and longevity. Wheels for these dual wheel casters can range from pneumatic, to polyurethane wheels to forged steel wheels to gray iron wheels.

Flanged Wheel Casters

Flanged wheels are designed to operate on a steel track for minimal guidance and rolling effort. Flanged wheel casters are rigid casters used for locating fixtures in a precise position for indexing through a work cycle and are ideal for Precision Alignment

Common applications for flanged wheel casters include captive turntables or repetitive processes, including foundry cooling lines.  Various bore sizes are available for use with keyway or a variety of bearings.

V-Groove Casters

V-Groove casters are rigid casters that travel on a pre-designed track. Typically, designed to carry loads of 1,000 lbs to 15,000 lbs., V-Groove casters are a very efficient method of carrying heavy loads over pre-determined distances. It’s very important that the hardness of the wheel and the hardness of the track “match” to ensure a prolonged life of the wheel and the track. If they are not matched, excessive wear can occur. V-Groove casters are highly adaptable and can operate on angle iron track or on normal floor surfaces.  Our experts are ready to help you correctly specify the proper components for your application.

Common V-Groove caster applications include industrial ovens, paint booths and other similar equipment. For special applications various sizes and shapes of grooves can be designed and machined to meet the most difficult and demanding applications.

Shock Absorbing Casters

Shock absorbing casters have swivel sections that are constructed of high alloy steel and are precision machined for close tolerances and long life. These casters feature legs of thick section plate steel. Integrally forged kingpins are available from 3/4 inch to 1-1/4 inch in diameter. In normal configurations, these swivel sections will carry 3 to 4 times their listed capacity. The spring compression starts with as little as 25 pounds loading per caster resulting in cushioned loads. The long swivel lead reduces excessive vibration while towing.

Shock absorbing casters are ideal for jet engine dollies, aircraft jacks, in-plant trailers, trash gondolas, lift truck stabilizer casters, revolving signs and parade floats.

Vertical Spring Loaded Casters

Vertical spring loaded casters offer a high flexibility in design to meet the specified application. Each caster features springs that are retained in a fixed position on a threaded rod for pre-load capabilities. The purpose of pre-loading a caster is to allow the caster to carry a load before it begins a spring deflection. Once the spring begins to deflect, the user should find a consistent spring reaction related to the load applied. These spring loaded caster wheels are built for the most rugged applications. Their box construction (formed or fabricated) can withstand abusive applications without changing the cycle life of the product.

Spring loaded casters are ideal for jet engine dollies, aircraft jacks, in-plant trailers, trash gondolas, lift truck stabilizer casters, revolving signs, parade floats and many other industrial applications. These casters can be designed to carry loads in excess of 20,000 lbs.

Vertical mounted spring casters are manufactured in standard sizes from 6 inches to 12 inches in height and accommodate wheels from 2 inches to 4 inches wide. These standard casters will carry loads from 500 lbs to 4,000 lbs.

Pneumatic Casters

Pneumatic casters are air-filled and designed for low speed, manually moved applications. Pneumatic casters are ideally suited for moving fragile or delicate cargo where the caster overall height is not critical. Pneumatic wheel casters are usually the best choice for use outdoors or rough surfaces (i.e. gravel) or on grass. The wide footprint on 8″ or larger pneumatic wheels provides stability on uneven surfaces both inside and outside. The pneumatic tires cushion the load and roll over obstructions with ease. These casters provide longer wheel life, less maintenance and high shock absorbency.  Generally speaking pneumatic casters can carry loads up to 7,500 lbs. in total weight.

Common pneumatic caster applications include aircraft ground support equipment, helicopter dollies, roof maintenance equipment, mobile construction shelters, and other equipment carrying electronics or other highly sensitive materials.

It’s important to note when selecting a pneumatic caster that capacity ratings are based on loads being moved manually with the proper tire inflation.

Stem Casters

A stem caster is simply a caster that uses a stem as a fastening device. Stem casters are more commonly available in the lighter weight categories, with capacities generally under 200 pounds each. The advantage a stem provides for lightweight usage becomes a disadvantage for heavier duty applications. The single point for securing; acts as an unwanted pivot point for larger capacities. An exception to this generality would be scaffold casters with a heavy stem for insertion into the scaffold tubing.

Stem casters are used on chairs, beds, and other household furniture. Outside the home, casters using a stem for connectivity are found on office chairs, office equipment carts, hospital carts and stands.

By having only one caster connection or fastener, stem casters are usually easy to replace. Medium to heavy duty casters are normally fitted with a top plate, giving 4 points for bolting the caster to a device, requiring tools for installation.  Grip ring stems and grip neck stems are inserted into a socket. This can usually be accomplished without tools. For removal, tools might be necessary to "unlock" the expanded grip ring, or to decompress the grip neck socket for release.

Another stem caster type is threaded, and as the name implies, the stem has threads and is inserted by turning into the socket with a clockwise motion.

Caster Spare Parts

Floor Lock Brakes

Floor Lock Brakes are designed for use on level surfaces and are not recommended for use on inclined surfaces. It is important to select a floor lock model that clears the floor when retracted. To adapt a floor lock brake to your present equipment, select a model with an extended height 1/16" to 1/4" greater than the overall height of the caster.


Common Floor Lock Benefits

  • Heavy duty industrial strength construction
  • Foot pedal easily activates lock with foot pressure
  • Non-slip, non-skid rubber brake pad holds securely on smooth or irregular floor. Designed for use on level surfaces.
  • Durable, high-compression spring for heavy loads
  • Conveniently located release bar retracts brake instantly with slight toe pressure to either side of the bar
  • Attractive zinc plated finish


Corner/Continuous Bumpers

Grey corner bumpers with matching strip bumpers provide 100% protection to the full perimeter of equipment. Strip bumpers are made with flat steel inserts for permanent attachment. Inserts in strip bumpers are not predrilled. They can be easily cut to size with a hacksaw and drilled as needed.

Temperature Range: -45°F to 180°F


Steel Inserts


Long side | Short side



Mounting Holes



6-3/16" | 3-1/16"



2(17/64") in 6" side
1(17/64") in 3" side



Specify (16 ft. max., 1 ft. inc.)




No Insert

Specify (50 ft. inc.)





2-5/8" each side



2(13/64") each side



Specify (16 ft. max., 1 ft. inc.)




No Insert

Specify (50 ft. inc.)





2-1/2" each side



2(1/8") each side



Specify (20 ft. max., 1 ft. inc.)




No Insert

Specify (50 ft. inc.)



*Strip bumper with insert available in 10, 12, 16 and 20 ft. pre-cut lengths.

End Bumpers

Generally used on the ends of tubular handles. Available in 3-1/4" and 1-3/4" diameters. Easily attached, they are soft enough to absorb noise and shock and hard enough to wear for years.













Corner Bumpers

A heavy duty bumper with an extra rounded buildup on the apex of the corner where shocks and wear are greatest. Ends are tapered and rounded. Each side is 3" long and 1-1/8" wide at the base.


Thickness at

Thickness at

Mounting Holes




2(3/16") on each side

Caster Wheels

Bastian Solutions stocks caster wheels in all sizes to meet your specific application. From cast iron caster wheels to polyurethane caster wheels to the user-specific v-groove caster wheels and flanged caster wheels, Bastian Solutions supplies the highest quality heavy duty caster wheels for all industrial caster wheel applications.

Industrial caster wheels are made for a variety of applications.  They are made for medium duty heavy duty or extra heavy duty applications, as most industrial applications involve some degree of abuse. The abuse can originate from a variety of situations, including:

  • Carts being tugged and transported by power equipment

  • “Shock Loading” a cart (dropping a load on a cart even if from a very short height)

  • Side thrust from the cart skidding or being pushed sideways

  • Difficult floor conditions (expansion cracks, potholes in the floor, or deterioration of the floors) which are impacted when the cart is heavily loaded and traveling at high speed

  • Environmental – exposure to a variety of chemicals or fluids that may degrade the tire

  • Temperatures – heat from the work situation or an oven that will damage the tire or bearing


Each wheel can then be fitted with a variety of different bearing types. The bearing type should also be a consideration with designing a wheel into a specific application.

  • Roller Bearings – Used for manual applications and walking speeds.

  • Precision Ball Bearing – Used for higher speed applications, will take less abuse, can be sealed for maintenance free applications-Best ergonomic impact on the application.

  • Tapered Bearing - Used for the most abusive applications and heaviest loads. Require maintenance to assure adjustment


There are other miscellaneous issues that always should be considered when designing applying a wheel to a specific application.

  • Impact the wheel will have on the running surface-Always consider which is harder, the running surface or the wheel. Ideally they should nearly match and for the purpose of preserving the running surface (generally a floor) the wheel should be slightly softer.
  • Environment – Solvents, foreign debris on the running surface, moisture of any kind (including water), potential contamination of the bearing and or the running surface.
  • Ergonomics – Will the cart be handled manually (maybe be tugged and then manually manipulated) and are there forces that should not be exceeded to eliminate injury.


Caster Replacement Parts

Bastian Solutions provides replacement parts for a wide range of caster manufacturers.  Contact us today for replacement parts needs.  Most parts are in stock and ready to ship.

It is not unusual the life of a caster can be prolonged by replacing a variety of components that can be easily replaced as wear parts of a caster.

Replaceable parts for a caster fall into three main categories.

  • Bearings – Any bearing with regular extended use. This could be tapered roller bearing, straight roller bearing or ball bearing. Generally the tapered and straight roller bearing require regular maintenance which includes regular greasing and with tapered rolling bearing
  • Axles – At times, in an abusive application, axles can become damaged. An axle may be bent or threads can be damaged during operation. It is a good practice when replacing axles to replace bearings to prolong the life of each.

Besides the parts listed below, we can assist you with custom parts and custom engineered solutions to meet any need that prolongs the life of your caster or wheel investment.

  • Replacement Axles
  • Spanner Bushings
  • Caster Bearings


Roller Bearings

Bearings contained by hardened washers. Capable of greater load than the same diameter ball bearing.


Precision Tapered Bearings

Effective for heavy loads. Absorbs excessive side thrust loading and can be used for high speed operation.


Precision Sealed Ball Bearings

Maximum rolling, no maintenance lubrication required. Quiet operation for medium- to heavy-duty loads.


Annular Ball Bearing

Bearings are machined with hardened raceways. Bearing is pre-assembled and the entire unit is mounted in the wheel.


Delrin Bearings

Extremely durable under a wide range of temperatures, corrosion resistant. Well suited for applications where excessive water or liquid is present.


Oilite and Bronze Bearings

Self lubricates during use. Resistant to corrosion and suited for wet applications, slow speeds, high heat and very low maintenance.

In addition to the parts listed above, Bastian Solutions can assist you with custom parts and custom engineered solutions.


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