Fast Answer
Pick wheel material based on floor + environment first. Then adjust for debris, duty cycle, and push force.
- Concrete indoors: Polyurethane is the default “most of the time” pick for durability + push force.
- Floor protection / quiet: Rubber or non-marking polyurethane, depending on load and duty cycle.
- Debris / rough routes: Harder polyurethane + larger diameter usually beats “softer” materials.
- Washdown / corrosion: Material is only half of it. Sealing + corrosion resistance matter more than most people think.
- Heat or aggressive chemicals: You need material compatibility checks, not guesses.
If you want the fastest engineering workflow, run the tools in order: Load → Wheel Material → Diameter → Push Force → Layout → Failure Diagnosis.
How to Use This Chart
- Start with the floor. Smooth floors tolerate more options. Rough floors punish small diameter and soft tread.
- Match the environment. Washdown, freezer, heat, and chemicals are where “general purpose” wheels die early.
- Factor in debris. Chips, slag, gravel, and expansion joints change what survives.
- Decide what you care about most. Service life, push force, floor protection, or noise.
Important: If your cart flexes, your floor has joints, or you turn a lot, your “real load” per caster is higher than the simple math suggests. That’s where most premature failures start.
Wheel Material Compatibility Chart
Use this chart to narrow the material fast. If you have frequent failures, jump to the “Rules that override the chart” section.
| Floor / condition | Best starting materials | Usually avoid | Common failure when wrong |
|---|---|---|---|
| Smooth concrete (clean indoor) | Polyurethane, Rubber (quiet) | Very soft rubber under heavy static loads | Flat spotting, high push force if undersized |
| Rough / imperfect concrete, expansion joints | Harder polyurethane, larger diameter | Small diameter, soft tread | Chunking, bearing damage, operator strain |
| Epoxy / coated floors | Non-marking polyurethane, Rubber (non-marking) | Hard nylon/phenolic when floor protection matters | Marring, chatter, vibration complaints |
| Tile / smooth finished surfaces | Rubber, Non-marking polyurethane | Very hard wheels when noise/floor risk matters | Noise, marring, traction issues |
| Outdoor asphalt / mixed terrain | Pneumatic, Terrain-rated polyurethane | Hard small wheels | Shock failures, poor mobility, bearing wear |
| Debris routes (chips, slag, gravel) | Chip-resistant polyurethane, larger diameter | Soft rubber, small diameter | Gouging, chunking, swivel lockup |
| Washdown / wet / corrosive | Washdown-safe polyurethane + sealed design | Unprotected bearings / mild steel hardware | Corrosion, seized swivel, bearing failure |
| Freezer / cold | Low-temp polyurethane, Nylon (clean floors) | Rubber that stiffens, soft treads that flat spot | Flat spotting, cracking, high push force |
| High temperature | Phenolic, Metal (where acceptable) | Standard polyurethane/rubber past temp limits | Tread deformation, hub/bearing damage |
| Chemical exposure | Nylon or phenolic (chemical dependent) | “General purpose” without chemical check | Swelling, cracking, tread separation |
Floor is usually the biggest driver of push force and failure. Reference: Floor Conditions for Casters.
Rules That Override the Chart
1) Debris and joints force diameter changes
If your route has expansion joints, cracks, or debris, wheel diameter matters as much as material. A “better material” on a wheel that’s too small still fails early.
- Frequent joints/debris: prioritize a larger diameter.
- Small wheels + debris: expect bearing damage and swivel lockup.
2) Heavy static loads cause flat spotting
If equipment sits parked under load for long periods, softer materials deform. This shows up as thumping, vibration, and “it’s hard to start moving.”
3) Washdown is a sealing problem first
In wet environments, failure is often corrosion and contamination, not tread wear. If your swivels seize, you need sealing and corrosion resistance, not a different tread compound.
4) Heat and chemicals require compatibility checks
For high temp or chemical exposure, “close enough” is what causes repeat replacements. Verify material compatibility and temperature limits for the environment.
Common Real-World Combinations (That Actually Hold Up)
Indoor carts on concrete (most warehouses)
- Material: Polyurethane
- Why it works: Good balance of durability and rolling resistance
- What usually goes wrong: Diameter too small for joints or debris
Operator comfort and noise-sensitive areas
- Material: Rubber or non-marking polyurethane
- Why it works: Lower noise and better floor protection
- What usually goes wrong: Soft tread used under heavy static loads
Outdoor and mixed terrain moves
- Material: Pneumatic or terrain-ready polyurethane
- Why it works: Handles obstacles and reduces shock
- What usually goes wrong: Using hard small wheels and expecting them to survive
Washdown
- Material: Washdown-safe polyurethane + sealed design
- Why it works: Better resistance to water ingress and corrosion pathways
- What usually goes wrong: Bearings and swivels not protected
Next Steps
If you want to turn this chart into a defensible spec decision, run the calculators in order. That’s how you reduce push force and stop repeat failures.