Selecting & Sizing Air Caster Systems for Heavy-Load Applications

October 30, 2025

Transporting heavy or delicate equipment inside a facility is one of the most demanding challenges in manufacturing and assembly environments. Whether you’re relocating a 20-ton press, a turbine, or an entire production cell, every move must balance safety, precision, and efficiency.

Air caster systems—also known as air bearings—use a thin film of air to float loads with near-frictionless movement, allowing operators to move massive equipment in any direction with minimal effort. But to get the best performance, proper selection and sizing are essential. At Airfloat, we help you select the right size based on your application, and here are some factors to consider.

1. Start with the Load

Before choosing an air caster system, you must know your load’s total weight, center of gravity, and footprint. These three factors determine the type, number, and size of air casters required.

Total Weight: Include all components being moved—tools, fixtures, and any attachments.
Load Distribution: Uneven loads can cause one or more casters to “bottom out.” It’s best to size for the heaviest expected imbalance.
Footprint: A wider or longer load may need more casters to ensure stability and even lift.

2. Evaluate Your Floor Conditions

Air casters rely on a clean, level, and non-porous surface to maintain their air film. Floors with cracks, gaps, or texture can reduce lift or cause inconsistent movement. Review flooring condition guidelines.

If your floor isn’t ideal, you might be able to use air casters with proper planning:

Increase caster size or airflow to maintain lift on uneven floors.
Use steel plates over porous or cracked areas.
Check for levelness across the entire move path; dips or rises can affect performance.

3. Choose the Right Air Caster Size

Air casters come in different diameters, each with a specific load capacity and air consumption rate. The correct size depends on both your load weight and available air supply.

Caster Diameter	Approx. Capacity (per caster)	Air Flow (SCFM)
12 in (305 mm)	3,000 lb	11
24 in (610 mm)	12,500 lb	22
36 in (915 mm)	31,250 lb	35

Note: Actual performance varies by floor surface and load configuration. Always verify with Airfloat engineering for accurate sizing.

When in doubt, opt for slightly larger casters to provide extra lift margin and reduce air consumption under load.

4. Plan Your Air Supply

A stable, clean, and adequate air supply is critical. Undersized compressors are a common cause of poor performance.

Consider these guidelines:

Pressure: We recommend having 80 PSI at the hand control.
Flow: Add up total CFM demand across all casters and include 10–15% safety factor.
Hose Size: Larger hoses minimize pressure loss – ½” to 1″ is typical for most systems.
Dry Air: Use moisture traps or filters to prevent leaks and maintain consistent lift.

Example: A 4-caster system using 24″ air casters may require roughly 70–80 CFM at 60 PSI to operate smoothly.

5. Think About Transitions and Movement Path

Air casters excel on smooth, sealed surfaces—but every facility has transitions: door thresholds, joints, ramps, or uneven tiles. Each of these affects sizing and air demand.

To maintain movement:

Smooth transitions with steel plates or ramps.
Avoid sudden level changes greater than ⅛ inch.
Plan movement paths with enough clearance and turning radius for both operators and hoses.

If frequent transitions are unavoidable, talk to Airfloat engineers about hybrid or powered solutions that combine air casters with drive systems.

6. Installation & Testing

Once your system is sized, follow a structured installation process:

Position casters evenly under the load.
Check all air lines for kinks and leaks.
Inflate gradually and confirm even lift across all points.
Test movement before traveling the full route.

Routine inspections help ensure long-term reliability. Check diaphragms, valves, and hoses periodically for wear or air loss.

For detailed setup steps, including hose connections, air supply checks, and initial lift testing, refer to the Airfloat Quick Setup Manual.

7. Real-World Example

An example of the air caster system’s potential comes from Airfloat’s work in aerospace manufacturing. At Bombardier Aerospace’s facility in Toronto, engineers created a custom “floating” assembly line using air-bearing transporters to move 12,000-lb aircraft fuselages between workstations. The system used compressed air to lift the transporter a few millimetres off the floor and enable precise, driverless movement from station to station.

In this instance:

The transporter structure sat on four 20-inch air-bearing skids.
The result: reduced setup and transition time, improved ergonomics for operators, and a smoother flow through the assembly process.

This case shows how properly selected and implemented air caster systems can transform heavy-load moves from major rigging operations into streamlined production steps.

Read the full case study here.

Conclusion: Partner with Airfloat Experts

Selecting and sizing an air caster system isn’t one-size-fits-all—it’s an application driven decision that affects safety, uptime, and cost. Airfloat has helped manufacturers move everything from satellites to nuclear reactor cores, and we can help you choose the right configuration for your unique application.

Talk to our team today to discuss your load, environment, and performance goals. We’ll recommend the right air caster sizes, compressor requirements, and layout for a smooth, efficient move.