Simple steps to protect your equipment, your team, and your bottom line

Casters may be small, but they carry a big responsibility—literally. From industrial carts and medical equipment to warehouse racks and office furniture, casters keep your operations moving.

But when a caster fails, everything stops.

Caster failure can lead to downtime, equipment damage, safety hazards, and unexpected costs. The good news? Most caster problems are completely preventable with the right product selection, proper installation, and routine care.

In this article, we’ll walk you through the most common causes of caster failure—and more importantly, how to stop them before they roll in.

Understand the Real Load

One of the most frequent causes of caster failure is misjudging the weight load. Many users calculate the total weight of the equipment and divide by the number of casters. Seems logical—but there’s a catch.

In real-world use, not all casters share the load equally.

For example, if your cart has four casters but uneven terrain causes one to briefly lose contact with the floor, the remaining three are suddenly under increased pressure. This uneven distribution can lead to cracked wheels, broken stems, or warped hardware.

What to do instead:

• Choose casters that each support at least 25–30% more than your actual per-wheel load.

• Account for both static load (stationary weight) and dynamic load (when the equipment is moving).

• When in doubt, overspec—it’s better to have capacity to spare than to run casters at their limit.

Select the Right Wheel Material for the Environment

Not all wheels are created equal—and even if a caster is rated for your load, the wrong material can still fail. Consider the flooring, temperature, chemicals, and terrain your casters will encounter daily.

For example:

• Rubber wheels will deteriorate quickly on rough concrete.

• Plastic wheels can crack under cold temperatures.

• Metal wheels may cause noise or damage to finished floors.

Smart material matches:

• Polyurethane: Versatile, durable, and ideal for concrete, tile, or multi-surface environments.

• Phenolic: Handles high heat and heavy loads—great for industrial use.

• Thermoplastic Rubber (TPR): Quiet and non-marking, perfect for hospitals, schools, or offices.

• Nylon: Rolls well on carpet and resists moisture.

Choosing the wrong wheel material leads to flat spots, delamination, cracking, or unsafe rolling—all of which shorten caster life and raise your replacement costs.

Install with Care: Mounting Matters

Caster failure isn’t always about the wheel—it’s often about the way it’s mounted.

Improper mounting leads to loosening over time, misalignment, or even the caster shearing off completely.

Tips for proper installation:

• Use the correct size bolts or stem inserts for your caster and application.

• Make sure mounting surfaces are flat and clean, especially for top plate casters.

• Tighten hardware evenly, and use thread-locking compound when appropriate.

• Periodically check for loosening, especially on equipment that sees frequent movement or vibration.

At Caster Central, we offer mounting hardware, tube ends, and sockets to make installation secure and stress-free.

Don’t Skip Maintenance

Casters don’t need a lot of maintenance—but neglecting basic upkeep is a fast track to failure.

Dust, debris, and moisture can work their way into bearings, slow down swivel action, and cause casters to jam or lock up.
High-load environments accelerate wear, and impact over thresholds or debris can damage wheels, even if they appear fine at first glance.

A basic maintenance routine includes:

• Inspecting wheels for flat spots, cracks, or signs of wear.

• Checking bearings for smooth rotation and quiet operation.

• Tightening mounting hardware and checking for wobble.

• Cleaning debris from wheel treads and swivels regularly.

Set a reminder every quarter (or monthly in demanding environments) to do a quick caster check. These inspections take just minutes and can extend caster life by years.

When in Doubt—Replace Early

One failing caster can lead to bigger problems:

• It forces the other casters to carry more load.

• It causes dragging, which can damage floors.

• It increases operator strain and safety risks.

If a caster is showing signs of wear, don’t wait until it’s completely broken. Replace it early to protect the rest of your equipment—and your team.

Final Thoughts: Be Proactive, Not Reactive

Caster failure doesn’t happen all at once—it happens slowly, from small decisions and minor oversights that accumulate over time. But with just a few proactive steps, you can avoid unexpected breakdowns, extend the life of your equipment, and maintain a safer, more efficient workspace.

Whether you’re running a warehouse, outfitting a hospital, or simply upgrading office furniture, Caster Central is here to help you choose the right components, install them correctly, and keep them rolling smoothly.