An Air Caster Rigging Kit was recently used by Waterloo Industries to relocate multiple heavy metal stamping presses weighing up to 50,000 lb. Waterloo, a major manufacturer of tool storage, cabinets, chests, and workbenches for professional mechanics, shops, health care facilities, and consumers, needed to reorganize its plant layout to increase productivity and overall capacity. However, the task was complicated because stamping presses are typically difficult to move due to overall weight, physical size, high center of gravity, and offset loadings. Air Casters accomplished the task with minimal disruption to existing operations.

The solution to moving the presses safely and quickly included using a Model 4LD27HL Air Caster Rigging Kit. This system is comprised of:

• 1 each: control console with an inlet on/off ball valve, and four self-relieving pressure regulators to individually adjust the pressure in each air caster;


• 4 each: 27 in. diameter Air Casters with 112,000 lb total capacity;


• 4 each: 1 in. x 20 ft long interconnecting hoses; and


• 1 each: 1-1/2 in. x 150 ft long main air supply hose with quick disconnects.

Once the air casters were placed under the press and inflated, using only 250 cfm air consumption at 40 lb per sq in. pressure, a fork truck tied to the load via a steel chain using a crisscross pattern was able to push and precisely control the press in all directions. The total move included five each 90 deg turns with a total linear distance of 600 ft, on an epoxy-coated concrete floor with sealed expansion joints.

Air Caster operation is based upon compliant air film technology: the load actually floats on a thin film of air 3 to 5 thousands thick. Therefore Air Casters offer the following advantages:

• omni- or four-directional motions for maneuvering around the 90 deg turns and in tight aisleways,


• precise positioning for final press location,


• protection of the epoxy-coated floor finish,


• and safe movement and control of the heavy stamping presses throughout the plant.

Air Casters require only 3-5 lb of effort per 1000 lb of weight on a standard smooth, sealed concrete floor surface. Therefore, moving the 50,000 lb press requires only 150-250 lb of force, a job easily handled with a fork truck.

Manufactured in diameters ranging from 12-60 in., Air Casters can transport loads from 200 lb up to thousands of tons. Aeris Corp manufactures standard as well as custom-designed machinery moving systems including individual Air Caster load modules, planks, pallets, paper roll-movers, multi-stationed turntables, and air or electric power driven steel transporters.