Castor Wheel Safety: Advice for Industrial Castor Wheels

Safety first: It’s important in any workplace. From the biggest machines to the smallest wheels, workplace safety is a key part of training that should not be taken lightly. In this article, we cover the main points of safety when using castors and wheels in a workplace setting. Follow these steps to prevent accidents and ensure castors are maintained and used correctly.

How to use swivel castor wheels safely at work

In manual handling settings, castor and swivel wheels are used on roller cages, dollys, trolleys and pallet trucks. They make it easy to transport materials in any direction.

Health & Safety Advice for moving cages, dollies and pallet trucks includes:

• Walking speed: move no faster than walking speed (4km/h). Speed increases the force on Castors both on the swivel head and on the wheels. The load capacities for manually propelled castors are tested at 4km/h (Walking Speed).
  • If you are towing castors behind a motorised cart, you will need to select a castor designed for Power Towing. These have stronger swivel heads and castor brackets.
• Push don’t pull: pushing puts less strain on the back than pulling
• Seek Help on Ramps: when pushing on a slope, ramp, or uneven surface, two people should be on either side to maintain a steady speed
• Heavy Items First: stack heavier items at the bottom to lower the centre of gravity and avoid tipping
• Don’t Overload: do not exceed the recommended load capacity of the set of castors, load above the load line, or above the operator’s eye level
• Use brakes: if you have braked castors, apply the brakes whenever the cage is stopped

All operators working with cages, dollies or pallet trucks should receive adequate training in these points to ensure workplace safety.

Key points for ensuring castor safety

As well as training all staff in how to use cages safely, managers should follow these steps to avoid accidents at work.

1. Carry out regular inspections

Inspect wheels every 2-4 weeks to stay on top of issues. Routine inspections can help identify wear, damage, or potential issues with castors and wheels. Unreliable wheels can stick or increase the force required to push or be difficult to control, causing risk.

To carry out a frequent castor wheel inspection:

• Check and tighten bolts and nuts to prevent loosening due to vibrations
• Check wheel surfaces for wear, damage, dust or debris build up
• Check that the wheels spin freely and that the swivel also turns without resistance

Encourage a proactive approach to maintenance to address concerns before they escalate. Give staff a clear way to report damage to castors and remove that cage from operations until the castor is fixed.

2. Respect weight limits for stability

Stick to the weight limits for each castor. These parts are engineered to manage up to a certain amount of weight. Where heavy-duty castors are required, they have extra parts, larger wheels and stronger materials to cope with the load.

Overloading castors can lead to Instability. Damage to bearings and fixings as a result of weights they are not built to support can cause collapses, and injury or damage to goods.

 3. Look out for loose connections

Roller cages vibrate a lot as they are moved over uneven surfaces, which can loosen bolts and screws. Checking the castors regularly will avoid accidents.

To secure fastenings:

• Use the right spanner size
• Tighten all four corners halfway before fully tightening all four to ensure the castor is attached evenly.
• The bolts should not be movable by hand
• Check regularly as they will loosen over time.

4. Keep wheels lubricated

Regular lubrication ensures the wheels can spin freely without wearing down. Stuck wheels cause accidents, so it is important to keep castors lubricated. This gives better performance for longer. It also reduces the need for replacements, saving money and reducing waste.

Every 6 months:

1. Clean: Use a soft cloth to wipe any dirt built up on the castor. Scrape off any larger debris with a knife.
2. Lubricate: spray with a suitable lubricant. Apply to all moving parts
3. Brush: with a soft brush such as a toothbrush to push the lubricant into narrow areas
4. Wipe: Use a second soft cloth to wipe any excess lubricant.

You can use any multi-use or penetrating lubricant, such as WD-40 or GT85.

5. Consider your floor conditions

If you find your castors are loosening frequently or the wheel surfaces are wearing down rapidly, it is worth considering whether they suit the type of floor they are used on.

• Gravel: wider, pneumatic castor wheels are suitable for outdoor use.
• Tarmac: rough tarmac and other bumpy surfaces create high vibration and noise, for which shock-absorbing castors may be the best choice. The friction of rolling on rough surfaces can also wear down softer wheel tyre materials, so choose a hard thermoplastic tyre.
• Concrete: choose soft rubber, hard rubber, polyurethane, or nylon wheels. Metal wheels can embed into concrete when carrying high loads and should be avoided.
• Vinyl: Polyurethane castor wheel tyres can protect vinyl flooring as they are flexible enough to leave no marks.

Replacing the wheels to suit the floors they are used on will increase the lifespan of both the floor and the castor itself, reducing downtime and improving safety.

Key takeaways:

With regular checks and maintenance, castor wheels can last longer and reduce risks in the workplace. It is important to schedule maintenance regularly to avoid missing damage that could cause an accident, as workplace injury claims and damaged stock can be costly for businesses. By training staff in safe castor use, carrying out regular maintenance, ensuring the castors are suitable for the flooring and checking for loose connections, you can create a safe working environment.