How to Identify and Fix Load-Bearing Issues in Heavy Duty Castors

Published 19/09/2025

Introduction
Heavy duty castors are the backbone of industries like automotive, steel, logistics, and construction in India. They are designed to handle loads from 250 kg to over 2000 kg per wheel. But even the strongest castors fail if load-bearing issues aren’t addressed.

This blog explains how to identify problems early and fix them, ensuring maximum life and safety from your heavy-duty castors.

Signs of Load-Bearing Issues

Flattened wheels – Permanent deformation due to overload.

Cracked tread – Often seen in rubber wheels under excessive load.

Bent mounting plates – Caused by shock loads on uneven floors.

Difficulty in swiveling – Overloaded bearings restrict movement.

Uneven wear – When one wheel carries more load than others.

Causes of Load-Bearing Failures

Overloading beyond rated capacity.

Ignoring safety factor (especially in uneven floors or outdoor use).

Incorrect wheel distribution – 3-wheel vs 4-wheel setups.

High-speed operations without suitable castor type.

 

How to Fix & Prevent Issues

1. Correct Load Calculation

Use Muvall’s formula:
Load per wheel = (Load + Equipment Weight) ÷ No. of wheels × Safety Factor

Example: A 1200 kg machine with 4 castors on uneven floors → Safety factor 2.2. Each wheel must handle 660 kg.

2. Choose the Right Heavy-Duty Castor

Heavy Duty Castors (HMP): Up to 600 kg, excellent for shock loads.

Extra Heavy Duty Castors (HDP): Up to 1000 kg, excellent for heavy industries.

Super Heavy-Duty Tapered Bearing Castors (TTBP): For extreme industrial loads.

3. Proper Mounting

Always use parallel mounting for fixed castors.

For long trolleys, use 2 swivel + 2 fixed or 6-wheel dynamic shift configuration for better load distribution.

4. Maintenance for Heavy-Duty Use

Lubricate bearings every 2 weeks in steel plants or foundries.

Inspect for cracks in polyurethane treads due to metal chips.

Replace bent brackets immediately.

5. Upgrading When Needed

If failures persist:

Shift from rubber to polyurethane.

Use forged steel with tapered bearings for high-impact industries.

 

Real-World Example

At an Indian auto-component manufacturing plant, material handling was a recurring challenge. The facility was using nylon wheels rated for 500 kg each on heavy trolleys carrying engine blocks. Despite being within rated load, frequent breakdowns occurred—wheels would chip under shock loads, and brackets would bend during sharp turns on uneven shop floors.

Muvall conducted a detailed audit and found two key issues:

Load miscalculation – The plant was not factoring in uneven floor conditions and sudden dynamic loads from forklift handling.

Incorrect wheel material – Nylon provided strength but lacked shock absorption and durability for continuous heavy-duty cycles.

We recommended upgrading to CI-core polyurethane castors with tapered roller bearings, rated for 900 kg per wheel. The results were immediate:

35% reduction in downtime due to wheel-related failures.

Improved load stability during transport of engine blocks.

Lower maintenance costs, as wheels lasted significantly longer even in high-impact conditions.

Lesson Learned: Even if the rated load seems sufficient, real-world conditions like uneven surfaces, shock loads, and continuous use demand stronger wheels and a higher safety factor.

 

Also read : A Guide To Choosing the Right Industrial Trolley Wheels for Heavy Loads Outdoors

 

Conclusion
Heavy-duty castors are strong but not invincible. The key to preventing load-bearing issues lies in correct load calculation, right material selection, and regular maintenance. With Muvall’s wide range of heavy-duty castors, Indian industries can ensure reliability, safety, and smooth operations.