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Why Polyurethane Wheels Outperform Steel in RV Frame Shops

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In the early stages of RV manufacturing, the frame shop is where structure, alignment, and weld prep come together. These work zones are demanding environments that often include hot weld bays, abrasive debris, metal shavings, slag, and constant movement of heavy carts and fixtures. While steel wheels have traditionally been the go-to choice in these areas, polyurethane wheels are proving to be a better long-term solution in most cases.

From reducing floor damage to improving safety and lowering noise levels, polyurethane wheels offer clear advantages that make them well suited for modern RV frame production.

Floor Preservation in a High-Impact Environment

Steel wheels cause significant wear on facility flooring. Their narrow point of contact and lack of cushioning can scratch, chip, or gouge concrete, especially when carts are moved while carrying heavy materials. Over time, this damage compromises epoxy coatings and causes flaking, particularly on seams or transition zones.

Polyurethane wheels help prevent these issues by distributing weight more evenly. The tread layer acts as a cushion between the cart and the floor, which reduces surface stress and improves rolling comfort. Many RV manufacturers that have made the switch report longer floor life and fewer interruptions for surface repairs.

Lower Noise Levels Without Sacrificing Strength

Steel wheels are among the loudest components in any frame shop. When carts roll across hard concrete under load, the impact between metal and floor creates echoing vibrations that add to an already noisy environment. This contributes to operator fatigue and raises safety concerns for teams working nearby.

Polyurethane wheels reduce noise significantly. The tread material absorbs vibration and minimizes the resonance that typically occurs with rigid steel contact. Even under heavy loads, these wheels roll more quietly and contribute to a safer and more comfortable workplace.

Shock Absorption That Protects Workers and Equipment

Frame carts often carry heavy loads such as axles, tubing, jigs, and steel hardware. When a cart equipped with steel wheels hits rough patches or runs over debris, the shock transfers directly into the frame and can affect both the structure and the components being transported.

Polyurethane absorbs more of that impact, reducing the jolt that travels through the cart. This helps protect sensitive parts during transport and also benefits the operator. By softening each bump, polyurethane reduces the repetitive strain and push/pull resistance that contribute to worker fatigue and musculoskeletal injuries over time.

Traction and Control on Dirty or Slippery Floors

Frame shops rarely operate under pristine conditions. It is common to see grinding dust, oil residue, and scattered welding debris on the floor. Steel wheels have limited surface contact and tend to skid or lose traction in these areas, especially when the cart is lightly loaded.

Polyurethane wheels offer better traction thanks to their ability to conform slightly to the floor surface. This added grip improves control and reduces the risk of carts sliding, particularly during final positioning or when aligning into welding fixtures. For carts that need to move with precision and stop securely, this makes a major difference in safety and usability.

Load Capacity Without Rust or Constant Maintenance

Steel wheels are often chosen for their ability to carry heavy loads, but polyurethane wheels can meet or exceed those same load ratings when paired with the right core. Polyurethane tread bonded to an aluminum or cast iron core is suitable for even the most demanding cart applications in frame fabrication.

For example:

  • A 6-inch polyurethane wheel with an aluminum core can support up to 1,200 pounds per caster

  • Flat tread profiles provide better load distribution and rolling stability

  • Maintenance-free rigs help reduce service interruptions and replacement frequency

In addition, polyurethane wheels resist many chemicals and oils commonly found in frame shops, and unlike steel, they do not rust or corrode under normal plant conditions.

Ideal Specs for RV Frame Shop Mobility

When specifying polyurethane wheels for frame shop carts, consider the following setup for long-term performance:

  • Wheel material: Polyurethane tread with aluminum or cast iron core

  • Tread profile: Slightly crowned tread that offers a balance between directional stability and maneuverability

  • Wheel size: 6 to 8 inches depending on floor surface and obstacle clearance

  • Rig type: Kingpinless or maintenance-free steel rig for shock and impact resistance

  • Load capacity: 800 to 1,200 pounds per caster

  • Mounting: Top plate mounting (typically 4" x 4.5") for structural strength

  • Optional features: Swivel locks or total-lock brakes for added control and safety

This combination provides smooth rolling, high durability, and safer handling under tough conditions.

Looking for a Better Polyurethane Wheel? We Have You Covered.

At Caster Connection, we focus on designing and delivering polyurethane wheels that perform in real manufacturing environments. Our proprietary formulations are trusted by manufacturers in industries such as automotive, aerospace, healthcare, and material handling. With millions of casters in use, our products are known for reducing maintenance, protecting floors, and improving ergonomic safety across a wide range of applications.

We offer multiple product lines to meet the demands of light-duty, standard, and heavy-duty environments.

CC Apex

CC Apex is our most versatile caster, available in orange or gray. It performs exceptionally well in both manual and towline applications and handles debris, noise, and floor protection challenges with ease. Known for its low push/pull force and longevity, CC Apex is a favorite in distribution centers, automotive plants, hospitals, and beyond.

  • Wheel widths: 1-1/4" and 2"

  • Load capacity: 400 to 1,500 pounds depending on diameter

  • Tread: Debris-repelling polyurethane with excellent grip and low decibel output

  • Core: Machined aluminum

2017 CC Apex Large Logo

6" CC Apex Kingpinless Swivel Caster

SKU: CC-2110-600200-40-T1

ALT-SKU: CCAPEX-6S-KP

  • Overall Height
    7-1/2"
    Wt. Capacity
    1,000 lbs.
    Wheel Width
    2"
    Wheel Diameter
    6"
$85.14

6" CC Peak Maintenance-Free Swivel CC Apex Caster

SKU: CC-3110-600200-40-T1

ALT-SKU: CCAPEX-6S-EMF

  • Overall Height
    7-1/2"
    Wt. Capacity
    1,000 lbs.
    Wheel Width
    2"
    Wheel Diameter
    6"
$120.94

6" CC Apex Rigid Caster

SKU: CC-1010-600200-40-T1

ALT-SKU: CCAPEX-6R

  • Overall Height
    7-1/2"
    Wt. Capacity
    1,000 lbs.
    Wheel Width
    2"
    Wheel Diameter
    6"
$54.08

6" CC Apex Kingpinless Swivel Caster

SKU: CC-2110-600200-40-T2

ALT-SKU: CCAPEX-6S-KP-TP2

  • Overall Height
    7-1/2"
    Wt. Capacity
    1,000 lbs.
    Wheel Width
    2"
    Wheel Diameter
    6"
$76.04

6" Stainless Steel CC Apex Kingpinless Swivel Caster

SKU: DC-S510-600200-45-T1

ALT-SKU: CCAPEX-6S-SS-KP

  • Overall Height
    7-1/2"
    Wt. Capacity
    1,000 lbs.
    Wheel Width
    2"
    Wheel Diameter
    6"
$247.03

6" CC Peak Maintenance-Free Swivel CC Apex Caster w/ Extended Swivel Lead

SKU: CC-3210-600200-40-T1

ALT-SKU: CCAPEX-6S-EMF-EXT

  • Overall Height
    7-1/2"
    Wt. Capacity
    1,000 lbs.
    Wheel Width
    2"
    Wheel Diameter
    6"
$115.56

6" CC Peak Maintenance-Free Swivel CC Apex Caster w/ Built-In Brake

SKU: CC-3210-600200-40-T1-BIB

ALT-SKU: CCAPEX-6S-EMF-BIB

  • Overall Height
    7-1/2"
    Wt. Capacity
    1,000 lbs.
    Wheel Width
    2"
    Wheel Diameter
    6"
$149.60

6" CC Apex Extended-Lead Kingpinless Swivel Caster

SKU: CC-2210-600200-40-T1

ALT-SKU: CCAPEX-6S-KP-EXT

  • Overall Height
    7-1/2"
    Wt. Capacity
    1,000 lbs.
    Wheel Width
    2"
    Wheel Diameter
    6"
$85.00

6" CC Apex Swivel Caster w/ Ideal-Stop Brake

SKU: BC-2410-600200-40-M1-B7

ALT-SKU: CCAPEX-6S-IS-TP7-OH10

  • Overall Height
    8-1/2"
    Wt. Capacity
    1,000 lbs.
    Wheel Width
    2"
    Wheel Diameter
    6"
$314.46
Shop the Full Line of CC Apex Casters

CC Apex HD

For higher-weight applications, CC Apex HD delivers the same ergonomic and floor-safe benefits as the original but with much greater load capacity. It handles rough surfaces, metal chips, and towline stresses without sacrificing smooth movement or safety.

  • Load capacity: 2,700 to 3,500 pounds

  • Tread: Thicker polyurethane with enhanced noise dampening and floor preservation

  • Core: Machined aluminum

2018 CC Apex HD Tagline Logo 1

8" X 3" CC APEX HD DUAL-WHEEL SWIVEL CASTER 10-7/8" OVERALL HEIGHT

SKU: DC-D320-800300-40-T9

ALT-SKU: CCAPEXHD-830-SKPD-TP3-OH3

  • Overall Height
    10-7/8"
    Wt. Capacity
    5,400 lbs.
    Wheel Width
    3"
    Wheel Diameter
    8"
$1,300.37

8" X 3" CC APEX HD DUAL-WHEEL SWIVEL CASTER 10-1/2 OVERALL HEIGHT

SKU: DC-D220-800300-40-T7

ALT-SKU: CCAPEXHD-830-SKPD-TP2-OH2

  • Overall Height
    10-1/2"
    Wt. Capacity
    5,400 lbs.
    Wheel Width
    3"
    Wheel Diameter
    8"
$970.00

8" X 3" CC APEX HD SWIVEL CASTER 10-1/2 OVERALL HEIGHT

SKU: DC-5520-800300-40-T7

ALT-SKU: CCAPEXHD-830-S-TP2-OH2

  • Overall Height
    10-1/2"
    Wt. Capacity
    2,700 lbs.
    Wheel Width
    3"
    Wheel Diameter
    8"
$359.83

8" X 3" CC APEX HD KINGPINLESS SWIVEL CASTER 10-1/2" OVERALL HEIGHT

SKU: DC-6120-800300-40-T7

ALT-SKU: CCAPEXHD-830-S-KP-TP2-OH2

  • Overall Height
    10-1/2"
    Wt. Capacity
    2,700 lbs.
    Wheel Width
    3"
    Wheel Diameter
    8"
$393.26

8" X 3" CC APEX HD KINGPINLESS SWIVEL CASTER 10-1/8 OVERALL HEIGHT

SKU: CC-6120-800300-40-T2

ALT-SKU: CCAPEXHD-830-S-KP

  • Overall Height
    10-1/8"
    Wt. Capacity
    2,700 lbs.
    Wheel Width
    3"
    Wheel Diameter
    8"
$319.80

8" X 3" CC APEX HD DUAL-WHEEL RIGID CASTER 10-7/8 OVERALL HEIGHT

SKU: DC-R320-800300-40-T9

ALT-SKU: CCAPEXHD-830-RD-TP3-OH3

  • Overall Height
    10-7/8"
    Wt. Capacity
    5,400 lbs.
    Wheel Width
    3"
    Wheel Diameter
    8"
$993.91

8" X 3" CC APEX HD RIGID CASTER OVERALL HEIGHT 10-1/2"

SKU: DC-6220-800300-40-T7

ALT-SKU: CCAPEXHD-830-R-TP2-OH2

  • Overall Height
    10-1/2"
    Wt. Capacity
    2,700 lbs.
    Wheel Width
    3"
    Wheel Diameter
    8"
$261.37

8" X 3" CC APEX HD RIGID CASTER 10-1/8" OVERALL HEIGHT

SKU: CC-1020-800300-40-T2

ALT-SKU: CCAPEXHD-830-R

  • Overall Height
    10-1/8"
    Wt. Capacity
    2,700 lbs.
    Wheel Width
    3"
    Wheel Diameter
    8"
$275.46

12" X 3" CC APEX HD KINGPINLESS SWIVEL CASTER TOP PLATE 6-1/4"-7-1/2"

SKU: DC-D320-012300-40-T9

ALT-SKU: CCAPEXHD-1230-SKPD-TP3-OH2

  • Overall Height
    15-1/2"
    Wt. Capacity
    7,000 lbs.
    Wheel Width
    3"
    Wheel Diameter
    12"
$1,624.29
Shop the Full Line of CC Apex HD Casters

CC Stout HD

CC Stout HD shares the same polyurethane as the CC Apex lines but uses a cast iron core and flatter tread profile. This gives it greater strength for heavy-duty tasks while still offering ergonomic push/pull performance, floor protection, and resistance to debris and flat-spotting.

  • Load capacity: 750 to 2,750 pounds

  • Core: Cast iron

  • Best for: High-load carts, harsh environments, and applications where durability is critical

2017 CC Stout HD Tagline Large Logo

6" CC Stout HD Swivel Caster

SKU: DC-5350-600300-40-T2

ALT-SKU: GC-0250-600300-40-T2

  • Overall Height
    7-1/2"
    Wt. Capacity
    2,000 lbs.
    Wheel Width
    3"
    Wheel Diameter
    6"
$191.60

8" CC Stout HD Kingpinless Swivel Caster w/ Built in Brake

SKU: CC-2151-800200-40-T1-BIB

  • Overall Height
    9-1/2"
    Wt. Capacity
    1,750 lbs.
    Wheel Width
    2"
    Wheel Diameter
    8"
$123.48

8" CC Stout HD Kingpinless Swivel Caster w/ Extended Swivel Lead and Built in Brake

SKU: CC-2251-800200-40-T1-BIB

  • Overall Height
    9-1/2"
    Wt. Capacity
    1,750 lbs.
    Wheel Width
    2"
    Wheel Diameter
    8"
$173.65

8" CC Axis Rigid CC Stout HD Caster

SKU: CC-7051-800200-40-T2

  • Overall Height
    11-1/2"
    Wt. Capacity
    1,750 lbs.
    Wheel Width
    2"
    Wheel Diameter
    8"
$105.53

8" CC Axis Dual-Swivel Maintenance-Free CC Stout HD Caster

SKU: CC-7151-800200-40-T2

  • Overall Height
    11-1/2"
    Wt. Capacity
    1,750 lbs.
    Wheel Width
    2"
    Wheel Diameter
    8"
$393.47

8" CC Stout HD Swivel Caster

SKU: CCSTOUT-830-S

ALT-SKU: DC-5550-800300-40-T7

  • Overall Height
    10-1/2"
    Wt. Capacity
    2,300 lbs.
    Wheel Width
    3"
    Wheel Diameter
    8"
$133.83

8" CC Stout HD Kingpinless Dual-Wheel Swivel Caster

SKU: DC-D350-800300-40-T9

  • Overall Height
    10-7/8"
    Wt. Capacity
    4,600 lbs.
    Wheel Width
    3"
    Wheel Diameter
    8"
$1,077.63

8" CC Peak Heavy Duty Maintenance-Free Swivel CC Stout HD Caster

SKU: CCSTOUT-MF-8S-TP2-OH2

  • Overall Height
    10-1/8"
    Wt. Capacity
    1,500 lbs.
    Wheel Width
    2"
    Wheel Diameter
    8"
$202.52

8" CC Peak Heavy Duty Maintenance-Free Swivel CC Stout HD Caster w/ Extended Swivel Lead

SKU: CCSTOUT-MF-8S-TP2-OH2-EXT

  • Overall Height
    10-1/8"
    Wt. Capacity
    1,500 lbs.
    Wheel Width
    2"
    Wheel Diameter
    8"
$200.24
Shop the Full Line of CC Stout HD Casters

Whether you're replacing failed steel wheels or planning a new cart design from the ground up, we can help you choose the best caster for your application. Our team offers hands-on evaluations, and we work closely with clients to make sure every recommendation delivers long-term value.

Contact us today to learn more about CC Apex, CC Apex HD, or CC Stout HD, and discover what polyurethane performance can do for your operation.

Not Sure What You Need? Let's Figure It Out Together

Caster selection isn’t one-size-fits-all. That’s why we offer the Caster Needs Eval — a personalized service to help you identify the best caster solution for your carts, floors, and workflows.

What’s included:

  • A quick review of your current caster setup and challenges

  • Tailored recommendations based on real-world use, not just catalog specs

  • Flexible rollout options to fit your timeline and budget

Whether you're dealing with floor damage, push force issues, or premature failure, we’ll help you find a smarter solution.

Request your free evaluation today and get rolling with confidence.

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