How to Use the Caster Load Calculator
Enter Total Weight
Input the total weight of your equipment, cart, or load that will be supported by the casters.
Select Safety Factor
Choose a safety factor based on your application. We recommend 33% for most uses, 50% for heavy-duty applications.
Get Your Results
Review the recommended load capacity per caster and select casters that meet or exceed this rating.
Why Proper Load Calculation Matters
Safety First
Overloaded casters can fail unexpectedly, causing accidents, injuries, and damage to equipment or products. Proper load calculations ensure safe operation.
Extended Lifespan
Casters operating within their rated capacity last significantly longer, reducing maintenance costs and replacement frequency.
Cost Savings
Selecting properly-rated casters prevents premature wear, reduces downtime, and avoids costly equipment failures.
Understanding Caster Load Capacity
What is Load Capacity?
Load capacity is the maximum weight a caster can safely support. This rating is determined through rigorous testing and includes factors like wheel material, bearing type, and mounting style.
Why Add a Safety Factor?
A safety factor accounts for:
- Dynamic loads: Impact and shock from movement, starting, and stopping
- Uneven weight distribution: Load may not be perfectly centered
- Floor irregularities: Bumps, cracks, and transitions create temporary overload
- Long-term reliability: Extra capacity extends caster lifespan
Recommended Safety Factors
- 25%: Light-duty, smooth floors, stationary equipment
- 33%: Standard recommendation for most applications
- 50%: Heavy-duty, rough terrain, frequent impacts
- 100%: Extreme conditions, critical safety applications
Common Caster Applications & Load Requirements
Industrial Carts
Typical Load: 500-5,000 lbs
Recommended: 4-6 heavy-duty casters with 50% safety factor
Medical Equipment
Typical Load: 200-800 lbs
Recommended: 4-5 institutional casters with 33% safety factor
Food Service
Typical Load: 300-1,500 lbs
Recommended: 4 stainless steel casters with 33% safety factor
Retail Displays
Typical Load: 100-500 lbs
Recommended: 4 light-duty casters with 25% safety factor
Warehouse Equipment
Typical Load: 1,000-10,000 lbs
Recommended: 4-8 heavy-duty casters with 50% safety factor
Furniture & Office
Typical Load: 50-300 lbs
Recommended: 4-5 light-duty casters with 25% safety factor
Frequently Asked Questions
What happens if I exceed the load capacity?
Exceeding load capacity can cause wheel deformation, bearing failure, mounting damage, and complete caster failure. This creates safety hazards and can damage your floors and equipment.
Should I calculate for static or dynamic loads?
Always calculate for dynamic loads. While static capacity (stationary weight) is higher, dynamic capacity (moving weight) accounts for the stresses of movement, which is how casters are typically used.
How does wheel material affect load capacity?
Different materials have different load capacities. Steel and polyurethane wheels typically handle higher loads than rubber or plastic. The wheel diameter also impacts capacity—larger wheels generally support more weight.
Do I need to consider the weight of the cart itself?
Yes! Always include the weight of the cart, frame, or equipment in your total load calculation, not just the payload it carries.
What if my weight distribution is uneven?
For uneven weight distribution, calculate as if the heaviest-loaded caster carries 50-75% more than the average. Or, base your calculation on the number of casters minus one to build in extra safety.
How often should I recalculate load requirements?
Recalculate whenever you change the application, increase payload, modify the equipment, or notice caster wear. Regular inspection helps identify when load calculations need updating.
Need Help Selecting the Right Casters?
Our caster experts are here to help you find the perfect solution for your application. With decades of experience, we can guide you through load calculations, material selection, and custom configurations.