Caster Push Force + Safety Factor Calculator
Estimate operator push effort (rolling + start/breakaway + grade) and size minimum per-caster rated capacity. Includes wheel material + diameter so you can see what actually moves the needle.
How to use this tool
Use this to justify wheel upgrades and swivel selection with numbers. Then validate with a quick shop-floor push test.
- Push Force: shows what operators feel on your route (floor + grade + swivel config + wheel choice).
- Safety Factor: gives a minimum per-caster rated capacity target for impacts, rough floors, and uneven load sharing.
- Wheel compare: change material + diameter to see reduction (or why it isn’t enough).
What this targets (for SEO)
If your route includes impacts, rough concrete, or side-load turning, consider kingpinless swivels for durability.
Inputs
Effective Crr = Floor Crr × Wheel Material × Diameter × Swivel Factor (unless overridden). Use for directionality, then validate with a push test.Results
Effective Crr used
—
Floor × wheel × diameter × swivel (or override)
Rolling push force (level + grade)
—
Force to keep moving
Start push force (breakaway)
—
Higher at start
Total start force (start + grade)
—
What operators feel
Operator Effort Gauge (total start force)
—
Enter values and click Calculate.
Nominal load per caster
—
Total load ÷ casters
Safety factor used
—
Severity × unevenness
Recommended min rating
—
Per-caster rated capacity
Recommended system rating
—
Min rating × casters
Sizing Risk Gauge (SF)
—
Enter values and click Calculate.
Calculator FAQs
How does wheel diameter reduce push force?
Larger wheels bridge cracks/joints and roll over debris with less “impact loss,” which effectively reduces resistance and operator effort on real routes.
What’s the difference between rolling force and start force?
Start (breakaway) force is higher because you’re overcoming initial friction and misalignment. Rolling force is the ongoing effort once moving.
What is Crr?
Crr is a rolling resistance coefficient. This tool uses a base floor value and then modifies it using wheel material + diameter. If you’ve measured it, use the override.
Why do all-swivel carts feel worse on rough floors?
More scrub in turns and more fighting alignment. That shows up as extra effective resistance, especially on rough concrete and debris routes.
Which wheel material usually lowers push effort?
On many indoor concrete routes, harder wheels (nylon / steel) roll easier, but they can transmit shock/noise. Polyurethane is usually the best “industrial balance.”
What safety factor should I use for caster sizing?
For smooth indoor carts, lower safety factors can work. For rough floors, impacts, towing, or downtime-sensitive equipment, use higher safety factors and heavy-duty swivel construction.
Is this an engineering standard?
No. It’s a fast estimator for direction and justification. Final specs should be validated with a shop-floor push test and application review.
How do shock loads relate to caster failure?
Impacts and floor transitions can spike forces above static load. Repeated shock accelerates raceway wear, loosens fasteners, and can damage swivel assemblies.