Many factories have plenty of old trolleys whose frames are still sound, but whose wheels are broken, stiff to push or unsuited to new work. Before buying a whole new fleet, see whether repair or modification is the better value.
Common Repairs and Modifications
- New wheels and plates: switch to properly rated cast-iron-core PU wheels and a new mix of rigid, swivel and brake casters for easier pushing
- Frame reinforcement: add cross members under sagging decks or braces at wobbly corners
- Crack repair welding: grind out cracks and re-weld, adding a reinforcing plate at load points
- Adding or adjusting shelves: extra levels, new spacing or drip trays
- Extra fittings: guard rails, new handles, part fixtures
- Repainting or rust-proofing: remove rust and repaint to extend frame life
When to Repair and When to Build New
| Condition | Recommended |
|---|---|
| Sound frame, broken or stiff wheels | Replace wheels and plates |
| Frame sags or wobbles in places | Reinforce the frame |
| Surface rust only | Clean and repaint |
| Rust has thinned the steel, or many cracks | Build a new trolley |
| Size no longer fits the work at all | Build new to drawings |
Start with the wheels: most hard-pushing or unstable trolleys can be fixed by replacing the wheels and re-arranging the casters — far cheaper than a new trolley. See our wheel + plate installation service.
What to Send for an Assessment
- Photos of the whole trolley and the damaged areas
- Photos of the existing caster plates with dimensions
- The load carried and what you want to change
- The number of trolleys to repair
Summary
If the frame is still sound, new wheels, reinforcement or modification usually beat buying new. If rust has eaten into the steel or there are many cracks, a new custom-built trolley is safer and better value in the long run.