Deadman Brake Casters Enable ADA-Compliant, Safer Airport Cart Operations
In airport environments, mobility is not optional — but uncontrolled mobility is a serious risk. Jet bridges, terminal corridors, and service areas demand equipment that moves smoothly when intended and stops immediately when it shouldn’t move at all. As airport operations evolve to meet stricter Americans with Disabilities Act (ADA) requirements and higher safety expectations, manufacturers and airlines are increasingly re-evaluating the components that keep mobile equipment under control. For airport service carts, braking systems are no longer a nice-to-have feature — they are a critical safety and compliance requirement. This case study highlights how a Deadman Brake caster solution helped an aviation equipment manufacturer overcome a high-pressure design challenge, meet ADA-related mobility requirements, and support large-scale airline deployment — all without compromising operator usability or production timelines.
The Challenge: Designing an ADA-Compliant Airport Cart Under Time Pressure
A fourth-generation aviation equipment manufacturer best known for producing jet bridge systems was tasked with developing a new mobile airport service cart to meet evolving ADA-related requirements.
Unlike fixed jet bridge infrastructure, mobile carts introduce additional risks:
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Sloped surfaces near jet bridge approaches
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Dense pedestrian traffic in terminals
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Frequent starts, stops, and hand-offs between operators
To comply with ADA expectations and airline safety standards, the cart needed to:
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Remain stationary when unattended
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Stop automatically if the operator released the handle
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Perform consistently across multiple airport environments
Complicating matters, the manufacturer had already received a large initial airline order and immediate interest from additional major carriers. Early test carts equipped with commodity casters failed to inspire confidence during evaluations, creating concern that the project could stall or require a costly redesign.
With airline approvals on the line, the manufacturer needed a proven deadman brake caster solution — and they needed it quickly.
The Solution: Deadman Brake Casters Engineered for Airport Safety and Control
Caster Connection partnered directly with the manufacturer’s engineering and operations teams to evaluate the cart application and recommend a Deadman Brake caster system designed for high-risk, high-traffic environments.
A Deadman Brake system automatically engages the brake when the operator releases the handle, ensuring the cart cannot move unintentionally. This design reduces reliance on operator reaction time and physical strength, making it especially valuable for ADA-compliant applications.
To accelerate decision-making and reduce development risk, Caster Connection provided a fully assembled demonstration cart featuring Deadman Brake casters. This hands-on approach allowed the manufacturer and airline operations teams to:\
- Test braking responsiveness in real time
- Evaluate ergonomics and ease of use
- Simulate airport-specific operating conditions
