Castor Arrangements for Hand Pushing Fallshaw banner
TO DO ITS JOB PROPERLY, A CASTOR MUST SWIVEL AND ROLL EASILY.
IT CAN ONLY DO THIS WHEN THE TROLLEY AND THE CASTOR
ARE THE RIGHT SIZE … AND THE CASTOR IS PROPERLY FITTED.
When the goods are to be moved in a relatively limited area, either during manufacture, or to and from storage, mobile trolleys are the easiest way.

Most industrial codes restrict the direct lift of an adult to 13-18Kg. Using wheels and castors allows this same person to move 600-1800Kg, but greater loads require mechanical assistance. Roughly, using modern castors such as ours, a fit adult can push 600Kg continuously, or 1200Kg for 10 metres or 1800Kg for 1 metre given appropriate tyres and floors. If greater loads are to be moved there is a clear case for towing the trolley with a tractor of some sort.

DESIGN OF TROLLEYS
The responsibility for the design of the trolley must ultimately rest with our customers. Good castors can make a well designed trolley work even better, but they cannot do much to improve a wrongly designed trolley. As well as these brief notes Fallshaws publish a brochure on "Designing Trolleys", and you are welcome to a copy.
In general the most comfortable shape for a trolley is one where the sides are about 11/2 to 2 times the width, and not too high.
A TROLLEY SHOULD BE:
NOT too WIDE: They have to go through doorways. Hand pushed trolleys have to be at least 80mm narrower than the narrowest doorway (and that is across the BUFFERS (corner, leg, strip) which should be fitted). Towed trolleys need to be at least 500mm narrower than the narrowest aisle or doorway, and more if towed in a train.
NOT too LONG: Otherwise it will not track smoothly around corners. If it must be long you may need to experiment to find the best castor arrangement to suit your particular needs.
NOT too HIGH: Most trolleys are restricted in width to suit the aisles, and will topple over if too high. High trolleys you cannot see over are a safety hazard.
NOT too LIGHT: As a rough guide the weight of the trolley is usually 15% to 20% of the load it is to carry. For the castor to function properly the frame of the trolley must be strong enough to hold the castor head truly vertical so it can rotate freely (that is the mounting plate must remain horizontal), and the frame must not bend under the impacts that invariably occur. The most common cause of castors not tracking properly is that the mounting has twisted off square.
NOT too HEAVY: It is often safer, and more efficient, to divide a heavy load over a number of trolleys rather than concentrating it into one. Trolleys which are too heavy to move conveniently remain unused, or people suffer back injuries.
Handle at convenient height for pushing (approx 1 metre high). If trolley is to be pulled (and most are at some time) put the handle far enough out to ensure feet do not hit trolley (approx 400mm)
Castor Arrangements for Hand Pushing
Direction of travel Maneuverability Stability Steering Comments
Trolley - 4 swivel Maximum.
Can be moved at right angles		 Good except on narrow trolley Erratic if moved quickly over uneven surfaces Most popular for confined spaces
Trolley - 2 swivel, 2 rigid Good except in confined spaces Very stable. Can negotiate ramps easily Accurate. Push with rigid castors leading if heavy loads or uneven surfaces For more open spaces or long runs (M, Q, D, J & H) have directional lock
Trolley - 2 swivel, 2 rigid, rocking Very good but cannot negotiate ramps Fair except if heavy loads placed on corner Accurate Rigid castors usually next larger size so will rock on two centre wheels
Trolley - 4 swivel, 2 rigid centre High. Can be turned in own length but not moved at right angles Most stable Best for long wheelbases and straight lines Centre castors can be equal or larger in height to end castors