Improving Manual Cart Mobility and Ergonomics with CC Nexus and CC Stout HD Casters
In heavy manufacturing environments, manual material handling carts carrying thousands of pounds must move safely, efficiently, and with minimal operator strain—even when travel distances are short. This case study highlights how a manufacturing facility dramatically improved cart mobility, ergonomics, and floor protection by replacing failing polyolefin casters with a heavy-duty solution engineered for high loads and uneven concrete. By implementing CC Nexus ergonomic swivel casters and CC Stout HD rigid casters, the facility reduced excessive push/pull forces, eliminated the need for multiple operators, and improved daily workflow reliability—demonstrating how proper caster selection plays a critical role in manufacturing safety, productivity, and long-term equipment performance.
The Challenge
A manufacturing facility in the metal fabrication/material handling industry was experiencing significant ergonomic and operational challenges with a heavy-duty cart used to move large assemblies. Although the cart only traveled a short distance (about three feet) between a load-in point and a processing station, operators consistently needed multiple people to manually pull and push the cart. This reduced productivity and increased the risk of strain injuries.
Originally equipped with 6” polyolefin kingpin casters, the wheels had cracked and deteriorated due to repeated stress—compounded by dips and crumbling in the concrete floor.
When Caster Connection conducted push/pull testing, the resistance was so high that force measurement equipment failed to register a meaningful reading, underscoring just how difficult movement had become under normal operating conditions.
The customer desired to maintain a 6” wheel diameter due to clearance constraints, but every attempted configuration at that size resulted in unacceptably high push-pull forces.
Identifying the Need for Change
The performance of the existing caster setup was compromising worker safety, product flow, and floor condition. With cart weights ultimately estimated between 3,500–4,000 lbs, it was clear that a heavier-duty, smoother-rolling solution was required to:
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Reduce push/pull force
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Improve operator ergonomics
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Accommodate floor irregularities
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Increase uptime and reliability
When keeping the wheel size small proved impractical, the in-house fabrication team agreed to adjust the cart design to accept a larger caster package—opening the door for a more effective solution.
Solution: CC Nexus + CC Stout HD Casters
To optimize both maneuverability and durability, Caster Connection recommended:
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CC Nexus 8” x 3” Maintenance-Free Swivel Casters for smooth, ergonomic movement and low rolling resistance
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CC Stout HD 8” x 3” Rigid Casters to provide load stability and long-term reliability
Because traditional brake options were unavailable, the team also recommended a floor lock to secure the cart once positioned—ensuring safe placement without compromising mobility.
This combination achieved a balanced solution that:
- Improved push/pull performance
- Increased load capacity handling
- Reduced physical exertion for operators
- Absorbed uneven floor conditions
Implementation and Results
Once the larger caster configuration was installed, operators reported a dramatic improvement in ease of movement, eliminating the need for multiple people to handle the cart. The CC Nexus swivel casters’ low-exertion, multi-wheel design helped reduce rolling resistance—meaning operators could move the heavy cart with significantly less effort than before .
The facility was so satisfied with the results that they upgraded all four similar carts within a few months to match the new caster setup.
Why This Matters
This case highlights how even short travel distances can cause substantial ergonomic strain when the caster configuration isn’t matched to load weight and floor conditions. By selecting the right combination of premium casters and collaborating with the customer’s fabrication team to adjust cart design, Caster Connection was able to:
- Reduce ergonomic push/pull forces
- Improve daily operational efficiency
- Extend caster and floor life
- Enhance overall workplace safety
Learn More
Discover how CC Nexus ergonomic casters and CC Stout HD heavy-duty casters can transform your material handling workflows by reducing strain, lowering push/pull forces, and improving mobility—even for heavy loads and challenging floor conditions.
