How it works

All we need is a suitable floor and air


The air casters exist of a flexible rubber membrane that is fed by compressed air operating from 15 to 60 psi. A controlled leakage of the compressed air creates a thin air film between the floor and the air caster. Because of that the air caster can now float a fraction of a millimeter above the floor with virtually no friction. As a result this makes it possible to move very heavy loads and sensitive objects with relatively low force. It only requires 1 lbs of pulling force to move a weight of 1,000lbs.

For example

One single air caster with a 15 inch diameter has a maximum capacity of 8,800 lbs!

The load itself is only raised by a few inches. Due to the relatively low flow, no dust cloud is created and the floor does not get damaged because there is no point-concentrated load. The noise level is also low due to the low pressure applied.

Step 1

The weight of the load is transferred to the ground via the landing pad.

Step 2

Compressed air is applied; the air caster’s membrane lifts the load from the ground.

Step 3

Air pressure overcomes the weight of the load; a controlled leak creates an air film and it floats.


The right kind of floor for air caster movement is characterised as being airtight, smooth and flat. An unsuitable floor can (temporarily) be improved to enable the air caster transport system to float. This can be done, for example, with metal or plastic sheets. Less suitable floors cause higher air consumption, friction and wear.

The ideal floor is mechanically power trowelled to a smooth, even finish. Any joints can be made suitable using a silicone filler.

If the floor is not level and you are handling heavy loads there is a risk that the object will drift away. This can cause dangerous situations if you don’t take the right precautions. In order to prevent your objects from drifting we can build in guide-wheels or drives.

Internal or external drives are being used when you have a reasonably level floor to control and brake the load. We would recommend using power drives on loads above 4 tons to be safe.


The basic principle of air caster transportation is that a thin air film is created between the air caster and the floor. To achieve this, you need to have sufficient air pressure and flow available at all times. The air needs to be dry and clean. Valves have been mounted on almost all installations in order to control the supplied pressure to the air casters. Because of that the air casters cannot be overloaded.

Insufficient air supply results in higher friction, more wear and even failure to function.

Facing internal transport challenges?