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Air casters

Do you need to move heavy objects or loads? Air casters offer a smart solution for effortless transport. The Air caster creates a thin layer of air between the object and the floor, allowing heavy objects to be moved smoothly while floating.

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What are Air casters?

Air casters allow you to move heavy objects with ease. The object floats on a thin film of air created by controlled airflow through the membrane.

This air film reduces friction between the object and the floor to just one-thousandth of its original value. As a result, you can move heavy loads, such as machines or other equipment, effortlessly and efficiently.

Because the load is evenly distributed, there is minimal risk of damage to the floor or the object itself—making air casters an ideal solution for flexible and efficient internal transport.

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How do Air casters work?

Step 1 – Placing and connecting
The caster is placed under the object and connected to a compressed air system. As soon as compressed air enters the membrane, the air caster activates, forming an airtight seal between the caster and the floor.
Step 2 – Object lifting
By inflating the caster, the object is lifted. The air fills the inner space of the membrane, generating an upward force that raises the object off the floor.
Step 3 – Pushing air out over the membrane
With increased pressure, air flows under the membrane in a controlled manner. This creates a thin air layer, allowing the object to float and become ready for movement.
Step 4 – Continuous airflow for floating motion
A constant airflow keeps the object floating. By balancing airflow and pressure, floor friction is drastically reduced. As a result, even heavy objects glide smoothly across the surface with minimal force.

What determines the capacity of an Air caster?

Surface area of the air caster – The larger the surface area, the more weight the caster can support. A larger surface area allows for easier movement of heavy objects.
Air pressure – The amount of air pressure the caster can handle directly determines its carrying capacity. There is a linear relationship: the higher the pressure, the more weight the caster can move. Standard air casters operate within a maximum pressure range of 1 to 4 bar.
Number of air casters – Using multiple air casters increases the total carrying capacity. A minimum of three air casters is required for stability, but the system is infinitely scalable. There is no weight limit as long as enough air casters are used.

“

After 20 years of loyal service, it was time for a new modular air caster transport system with an increased capacity of 24 tons. Air casters do not damage the floor and we can position our machines very accurately and with little effort. With an Air caster system we can provide companies that regularly have machines in their factory. moving, recommend using Aerofilm Systems air casters!

Jeroen Bender – General Manager, Bendertechniek BV

Wich floor is suitable?

For optimal air caster performance, the floor must be flat, smooth, and airtight. A suitable floor reduces air consumption and improves efficiency.

Uneven or damaged floors can negatively affect air caster performance and shorten their lifespan. In some cases, poor flooring conditions may even prevent the system from functioning.

How do you make the floor suitable?

A floor that is not naturally suitable for air casters can be easily modified:

Use an overlay. Cover the floor with a hard, rigid film or sheet to create a flat, smooth, and airtight surface.
Seal gaps or openings. Prevent air leakage by sealing gaps or cracks with tape or other materials.

These modifications are relatively simple and make almost any floor suitable for air casters.

Moving objects between different rooms

When transporting heavy objects between different rooms using air casters, careful planning is essential. Key considerations include:

Ensure the compressed air hose is long enough or can be easily redirected if necessary.
Account for hose diameter. A longer hose requires a suitable diameter to avoid excessive pressure loss.
Check floor conditions. Floors in all rooms must be suitable for air casters. Joints or thresholds can be obstacles—remove or bridge them. Sealing joints ensures optimal operation.

Proper planning keeps object movement between rooms safe and efficient.

Different names for air casters

Air casters are often referred to by different names, even when the technology remains the same. Common terms include air casters, air skids, and air skates—all of which refer to the same system.

Other synonyms include air bearing casters, air bearings, and air casters. These names emphasize how air is used to lift and transport objects. While the terminology varies, the function remains the same: an efficient, safe way to move heavy loads without traditional lifting equipment. No matter what it’s called, it is ultimately the same tool.