Here is a selection of FAQs regarding Air Casters and how they work. If you have a question that
is not covered here, please use the Contact Us page to send in your question.
+ What are air casters?
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Air Casters are devices that are designed to lift heavy loads using compressed air as its power source. Think hovercraft here. Used in a series of 4 or more, air casters form powerful load moving systems that can lift amd move heavy loads up to 100 tons.
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+ How big are air casters
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Air casters tend to be just a little larger than the air bearings that are fitted to it. In general, air casters start at 12 inches and go through a range up to 48 inches.
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+ How are air casters powered?
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Air casters are pneumatically powered - by compressed air which is sufficient to power up and drive the air casters and bearings. For moving your loads on an air caster system this is all you need. However, you will still require the necessary power to run your compressor and other peripheral equipment as normal.
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+ How do air casters work?
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Air casters work in a series of 4 or more to form powerful load moving equipment. Air casters are powered by compressed air that enters a series of air chanbers in the air caster module and exit into the air caster diaphragm. From there the diaphragm is inflated causing an air-tight seal with the floor surface, which then causes the load on the air casters to float on the floor surface - think hovercraft here. The load can then be moved away laterally.
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+ Air casters floor surface requirements
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To operate correctly air casters require a floor surface that is flat, level, even, smooth and non-porous.
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+ Are air casters easy to assemble?
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Yes they are. Air casters supplied by Hovair Systems mostly arrive in a kit form that includes everything you need to be up and running quickly. The air caster hose lines that are supplied with the kit are all equipped with quick disconnect fittings at either end. To connect an air caster, simply snap a hose on, lock doewn the fitting and you are in business. Very easy to connect and disconnect.
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+ How does everything connect up?
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For an easy set up you will need to lay out your air casters on the floor in a rough footprint of the load that is going to be moved. On a standard air caster system a hose is connected to an air caster module, the other end connects to a simple manifold or optional remote control box. Each air caster will connect the same way until you have an air manifold with four hose lines connecting from the manifold to the air caster module.
From the manifold you will have an air hose leading to a two-way ball valve which becomes the entry point for the system's air source to connect to.
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+ How do I connect the air casters to the compressed air source?
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The entry point of an air caster load moving system is usually at a two-way ball valve that can allow compressed air entry to the system or turn off the air to the sytem. Most factories, shops and warehouses have a compressor - usually outside - which supplies compressed air to various points through their buildings.
To connect an air caster system to the compressed air network, you simply locate what is known as an air drop point and plug in a connection that will take air to the ball valve entry point of the system.
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+ How many air casters do I need?
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This all depends on the weight and the size of the load you are looking to move. Loads of a standard size, say, 8ft x 4ft can easily be handled by a four station system. Sometimes you might encounter a load that really has all its weight on one end of the footprint. In such cases you would want to consider placing 4 air casters underneath the really heavy end and 2 others under the lighter end. This would need a 6 station system. Sometimes it might be preferable with a really long load to have a set of 4 air casters on each side of the load. There are many variables - and Hovair Systems can help you with this.
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+ Are air caster systems modular?
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Yes they are. Assembled in series of 4 or more air casters, you may have a load that requires extra support in a certain area of the load. With the other 4 air casters supporting the main area, you would need to extend your system and snap another load module on to it to support that certain area. Simply remove the blocked end of one tee-piece in the system and plug another hose line into it and you now have a set of 5 air casters - all interchangeable. You can add as many modules as you like to a system but they should all be of the same type and size.
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+ Can I mix air caster sizes?
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No. Hovair Systems does not recommend this practice. It is far better to have a system of air caster modules that are all the same in size and weight capacity. If, for instance, you were to already have, say 2 x 16-inch air caster modules with air bearings fitted, and you wanted to add them to a 22-inch system - you could technically do that, but in reality, the two 16-inch air casters would be the same height when resting on the floor surface, but when they were enegized with compressed air, they would not rise to the same height as the 22-inch casters. This would certainly cause problems when trying to move the load with these two additional air casters fitted.
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+ What is an air casters footprint?
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An air casters footprint is the amount of space (square feet) it takes up when being readied for a load moving exercise. We always recommend that when setting up your system for a load moving operation you should place the air casters on the floor in the rough shape of the load that is to be moved. This shapes is known as the footprint. Conversely, the footprint can also define the actual floor space a machine or load takes up on the floor surface.
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+ Can I change the air source point in mid travel?
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Absolutely, you can. When moving a load using air casters, at some point along the travel path you are going to possibly run out of hose. This is normally the amount of air hose at the time of plugging into the initial drop point. When this occurs, do not touch the air caster system. Leave everything as is and make sure the load is at a complete stop. Turn the ball valve to the OFF position. Unplug the hose line from drop point one and plug it into the next convenient drop point. Turn the ball valve back ON. At this time, the load will re- energize itself with compressed air and carry on with operations.
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+ What are the types of air casters?
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There are 4 types of air casters that Hovair Systems use for thier load moving equipment operations. They are all a little different and operate in a different way to the others. The types of air caster modules are: Round Steel, Square Aluminum, Low Profile Aluminum, and VL Stainless Steel.
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+ Air casters - heavy duty or standard?
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Apart from the obvious cost difference, the only difference between standard and heavy duty air caster load modules is their weight capacities. Heavy duty air bearings do tend to use a little more compressed air than the standard air bearings. Heavy duty air bearings will virtually double the weight capacity of the standard bearing of the same size. Everything depends on the variables for the load moving operation: size, shape, weight, height etc. Sometimes moving up to a 6 station system as against going for a heavy duty version of a 4 station system, will work better for you. By doing this, you will increase the weight capacity by approximately 50% and also add 2 more modules for additional support where needed. However, every systems is different, so ask your Hovair contact which will be the best system for you.
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+ What about uneven load weights?
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Many loads are going to be uneven - especially in heavy machinery. There is no way that can be overcome. The load is what it is and we have to find a way to shift it regardless of its disproportionate weight. Very often an air caster placed underneath the load at each corner will be sufficient providibg the weight capacity of the system is greater than the actual load being moved. Sometimes it is not the case, however, as a load may be, say, 10 ft long and weigh 10 tons with the majority of the 10 tons being on the last 2 ft of the load. In such cases you will need to opt for a 6 station kit so you can add 2 extra support modules under the really heavy areas. This will ensure that the load will be moved in a safe manner.
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+ How do you change an air bearing?
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Changing an air bearing is a relatively easy job. If you are working with load moving equipment with A-type air bearings fitted, all you need to do is located the damaged air bearing, turn the caster over so you can see the air bearing diaphragm. If you are working A-type air bearings, there is only one bolt to remove - that is in the center. Remove the bolt, remove the load pad and lift off the damaged air bearing. Replace the air bearing, replace load pad and bolt it all back together again.
If you are working B-type air bearings the process is exactly the same as the A-type process except that the B-type air bearings have an additional 4 screws - one at each corner - that need to be removed before removing the damaged air bearing. Then foolw the process for the A-type air bearing.
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