How do I size heavy duty casters for a cart?

Divide the total cart weight plus payload by 3, not 4 — on uneven floors only three wheels can touch the ground at once. Choose the next size up when the floor is rough or the cart is moved frequently.

What wheel diameter should I choose?

Larger diameters roll easier and bridge floor gaps better. For loads above 1000 kg per caster we recommend 200 mm or larger wheels.

Heavy Duty Casters (500–2000 kg per wheel)

RollMaster heavy duty casters cover the RM-Medium (150–500 kg), RM-Heavy (500–1500 kg) and RM-Extreme (1500 kg+) series, with wheel diameters from 100 mm to 300 mm. Every bracket is welded and load-tested on dynamic testing rigs before assembly.

Typical applications: machinery moving skates, die carts, heavy trolleys, warehouse platforms and equipment that must roll every working day without maintenance windows.

Spécifications

Load capacity 500–2000 kg per caster (count 3 of 4 casters at full load for uneven-floor safety)
Welded heavy-gauge steel brackets, zinc or powder-coated finish
Precision ball or roller bearings, lubrication fittings as standard
Dynamic load testing on every production batch

Finitions

Zinc plating, chrome plating, powder coating

Bracket finish	What it does	Specify it when
Zinc plating (blue/white)	Baseline corrosion protection	Standard dry indoor use
Chrome plating	Hard, decorative, easy to clean	Visible / cleanroom-adjacent equipment
Powder coating	Custom color, good corrosion resistance	Brand colors, outdoor-adjacent use
Stainless steel 304	No plating to fail	Washdown, food, medical
Stainless steel 316	Resists chlorides	Salt, brine, marine air, harsh cleaning chemicals

Essais

Wheel concentricity and bracket alignment per internal QC standard; load ratings based on EN 12530 testing protocols

Selection factor	Rule of thumb	Effect on performance
Load sizing	Total load ÷ 3 (not ÷ 4)	On uneven floors only three wheels carry the cart
Wheel diameter	Bigger rolls easier	Larger wheels cut push force and bridge gaps
Tread hardness	Softer = quieter, harder = easier rolling	Pick the softest tread that carries the load
Bearing choice	Precision ball for manual pushing, roller for heavy loads	Bearings dominate rolling resistance at high load
Swivel vs rigid	2 swivel + 2 rigid is the standard cart setup	All-swivel carts wander; all-rigid carts cannot steer
Floor condition	Rough floors need bigger wheels and softer treads	Small hard wheels on bad floors destroy both

Capability commitments on this page are owner-confirmed (2026-09-29).