Caster Concepts Casters are, BY FAR, the Best, Most Bulletproof HD Casters I Have Ever Seen
— Greg Sykes, Maintenance Director, Autovol
The Situation:Autovol, a global leader in automated modular home construction, operates at a high level in terms of building innovation. But even in an industry defined by progress, they were stuck in a costly maintenance loop. Every three years, the casters supporting their high-capacity modular transport systems needed full replacement—a process that cost more than $50,000 per caster, factoring in labor, equipment, and downtime.
The underlying issue? Traditional casters simply couldn’t withstand the demands of moving modular builds exceeding 50,000 lbs., resulting in excessive wear and frequent failure.
Enter Caster Concepts, a material handling solutions provider specializing in high-capacity casters. Tasked with the challenge of designing a system to move modular homes that exceed 50,000 lbs., Caster Concepts engineered a solution utilizing ten 81-series heavy-duty casters capable of handling a load of over 10,000 lbs. each. Engineered with a high-strength, single-ball race swivel design, these casters offer exceptional durability, smooth operation, and resistance to shock loading—ideal for the rigors of modular construction environments.
Five years later, not a single caster has been replaced. That’s nearly double the lifespan of the previous solution—and counting. This was a significant achievement, as maintenance and replacing the old casters cost the company more than $50,000 per caster. The switch to Caster Concepts casters has eliminated recurring maintenance, slashed replacement costs, and significantly reduced downtime.
Beyond cost savings, the improved caster design has also:
For a company like Autovol, where every efficiency counts, this upgrade has been a game-changer.
This success story highlights Caster Concepts’ dedication to providing reliable, long-lasting solutions tailored to their clients’ unique challenges. It also exemplifies how proper heavy duty caster design reduces the frequency of replacements (saving the cost of new casters and downtime), enables greater loads per cart, and reduces stress injuries.
As a trusted partner in Autovol’s expansion, Caster Concepts continues to showcase the lasting impact of its commitment to quality and innovation in the modular home industry. To find out more, contact us or call 888-781-1470.
