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The Warehouse Cart Buyer’s Guide
A warehouse cart is a simple piece of equipment, but on the floor, every second counts. If material handling equipment (MHE) isn’t suited to the task — or not capable of handling the load — productivity suffers.
Warehouse carts are the true workhorses of your facility. When outfitting, it’s important to choose solutions that will provide a return on investment. Here’s what you need to know.
The Warehouse Cart Buyer's Guide: Table of Contents
- What Is a Warehouse Cart?
- Warehouse Carts: Types and Features
- Choosing Warehouse Carts for Your Operation
- Using Warehouse Carts to Optimize Throughput
What Is a Warehouse Cart?
We all know what a cart is, generally, but a technical description will help us explore the topic, so here's our definition: A cart is a container, shelf, or similar carrying surface mounted on wheels. You usually push or pull carts by hand. They’re built to simplify the task of getting a load from one place to another.
But what makes it a warehouse cart in particular? Here’s our definition of warehouse cart:
A warehouse cart is a manually operated carrying device that features four or more wheels and a flat load-bearing surface (or surfaces), designed for industrial material handling.
Cart specifications like shelf size, carrying capacity, and frame shape are optimized for common warehouse materials: cartons, pallets, loose stock, machine parts, or more specialized items.
Technically, the Materials Handling Institute (MHI) refers to what we call a warehouse cart as a floor hand truck, which MHI defines as a “four-or-more-wheeled hand truck with handles for pushing or hitches for pulling, sometimes referred to as a ‘cart’ or ‘(manual) platform truck.’”
Warehouse carts don’t have forks for lifting pallets; such a carrying device would be a pallet jack or a lift truck. Instead, they have flat surfaces like shelves. Loads sit on these surfaces, which may include raised edges or slopes to keep objects contained.
They’re ideal for carrying warehouse loads:
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Horizontally across flat travel paths with no barriers.
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Up or down ramps that aren’t too steep.
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With moderate flowthrough rates that don’t justify automated conveyors.
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In scenarios with variable travel paths (as opposed to cranes, for instance, which can only move along a set travel path).
These conditions make warehouse carts ideal for order picking, stock putaway, line feeding, and other day-to-day material handling tasks. But there are many types of warehouse carts available. To choose the right one for your facility, it’s important to understand the options.
Warehouse Carts: Types and Features
1. Stock Picking Carts
Stock carts are ideal for moving merchandise, gathering parts, and order picking. Typical units have multiple shelves and a slim profile, which allows the cart to be maneuvered through tight aisles. Shelves may have edges or lips to contain contents during transport.
Options from BHS Include:
With a load capacity of up to 3,000 lb (1361 kg), OPCs are durable options for all types of warehouse operations. Each unit is equipped with two rigid and two swivel casters (poly or phenolic), with edged shelves and a powder-coat finish.
Standard OPCs feature a depth of 36" and an overall width of either 48" or 60". Custom options are available to meet the needs of specific applications.
Stock Picking Carts feature ergonomic handles and an integrated step ladder. Ideal for order-picking and stock put-away tasks, the SPC features three lipped shelves and a 1,000 lb (463 kg) load capacity.
Standard models are available with an overall depth of 36"-48" and an overall width of 22" or 28".
In certain applications, angled shelves can improve throughput and reduce ergonomic strain for workers. The ASC-3672 is designed for high-volume use, with three high-capacity shelves in a mesh-enclosed frame.
Optimized for bin picking and package handling, the Angled Shelf Cart features easy-steering casters and a 2-degree rearward grade that keeps contents secure. The two top shelves can carry up to 500 lb (226 kg) each, while the bottom shelf supports up to 1,500 lb (680 kg).
2. Bulk Quantity Warehouse Carts and Trucks
High-capacity units typically have larger surfaces and more casters than standard stock carts. They may be configured for specific applications (such as manufacturing or construction) or for certain types of loads.
Options from BHS Include:
As the name implies, Flat Deck Carts are low-profile platforms designed for bulk transport. Six heavy-duty casters minimize friction and ensure a high weight limit (variable by model). The wheels can be braked when not in use, and integrated fork pockets enhance maneuverability.
The FBC is also designed for large, heavy items. A unique caster alignment allows operators to move loads wherever they need them: Four 6" casters support loads of up to 2,000 lb (907 kg), while two central 8" casters allow for center-steer maneuverability.
Flat Stacking Carts offer adaptable material handling solutions for various industrial settings. Featuring four detachable steel posts, these carts enable stacking to save space between uses.
3. Security Carts
Security carts are designed for the transport of tools and other high-value items. Excellent for outdoor and publicly accessible job sites, they’re constructed with heavy-duty materials for years of dependable use.
Options from BHS Include:
Mobile Storage Cabinets (SEC-CS-1k-3060-VC)
This bi-fold industrial cart opens along a central seam into a single 10-foot long shelving unit. Its clamshell design provides plenty of room for storage, while the smooth-rolling casters allow for easy positioning.
This flagship product features three steel shelves that are adjustable in 3-inch increments. Its doors open to 180 degrees, providing convenient access to up to 5,000 lb (2,267 kg) of high-value supplies.
BHS manufactures a range of other Security Carts to meet the needs of common applications. As with our other material handling solutions, the features of each unit can be fully customized.
4. Utility Carts
Utility Carts are ideal for order picking, janitorial equipment, manufacturing components, and any task that requires the movement of bulk materials. They’re typically smaller than order picking carts, but may be more appropriate for general use.
Options from BHS Include:
BHS Utility, Service, Material Cart (USC)
The low-profile USC rolls smoothly and easily, even when loaded. An ergonomic angled handle enhances maneuverability, and each unit has a 1,000 lb (463 kg) capacity. Various configurations are available to serve different applications.
5. Panel Carts and Cantilever Carts
Industrial carts can also provide mobile storage for awkward materials — sheets of drywall, rigid conduit, and other products that cannot be safely transported with flatbed carts.
Options from BHS Include:
Panel Carts have a 1,000-lb (463 kg) capacity and are ideally suited to moving drywall, plywood, folding tables, and other flat materials. A carpeted deck protects products from damage. Removable handles make loading/unloading much easier, and the length/width can be customized to meet the needs of your facility.
Cantilever Cart (CCA2.5K-3974-86-5)
Cantilever Carts are designed to hold rigid conduit, pipes, bars, and other long, narrow materials. This steel-framed rolling rack features four sets of cantilever shelf arms, each adjustable within 2-inch (50-millimeter) increments.
Add additional shelf arms, or remove them to accommodate taller products. With 39-inch (991-millimeter) arms and a carrying capacity of 500 pounds (227 kilograms) per shelf (total unit capacity: 2,500 pounds [1134 kilograms]), this Cantilever Cart handles high volumes to maximize operational throughput.
Vertical Material Racks are also optimized for bars, pipes, and similar materials, but the VMR is engineered for long-term storage. The varying height of the crossbars allows a single unit to store up to 3,000 lb. (1361 kgs) of materials of different lengths.
Choosing Warehouse Carts for Your Operation
With all the options available, it can be difficult to know which cart will provide the best return on your material-handling investment. Consider the following factors when choosing a warehouse cart, says MHI:
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The size of the materials you plan to carry.
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The weight of a standard load.
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The best height from which to load and unload the cart.
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Potential ergonomic risks associated with operating the cart.
With these data points in hand, look for specifications that match.
Look at the size of your materials, for example. If you plan to move lots of 16-inch-high cartons, choose a BHS Order Picking Cart, which features nearly 18 inches of vertical space between shelves. If you need to carry four-foot boxes, however, you’re better off with a Flatbed Cart, which has no upper limit on carrying space.
As for the weight of warehouse materials, MHI recommends loads of no more than 2,000 to 2,500 pounds for manually operated carts. Above that, employers should provide powered assistance, such as tuggers or powered pushers.
Choose carts with carrying surfaces that allow the most workers to keep loads between their shoulders and knees. This is the ergonomic “power zone,” and will make loading and unloading carts safer. On another ergonomic note, choose models with comfortable push bars whenever possible.
You may not find an off-the-shelf warehouse cart that meets all your exact specifications. That’s when it pays to seek out custom material handling solutions from BHS, Inc.
Using Custom Warehouse Carts to Optimize Throughput
While standard warehouse carts can suit the needs of most facilities, a little customization can go a long way. BHS provides extensive customization options for all material handling equipment, including the warehouse carts and trucks listed above.
To start designing the ideal custom material handling cart for your use case, request a quote to start the conversation with our engineering team. We’ll propose a design, then make necessary iterations to match the equipment to your workflow.
All BHS warehouse carts feature heavy duty, powder-coated steel, reliable casters, and ergonomic designs. View our full selection of Industrial Carts or call 1.800.247.9500 to speak with a member of our sales team.