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  • How Can You Reduce Risk in Materials Handling with Proper Use of Single Flange Wheels & Trolley Syst
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How Can You Reduce Risk in Materials Handling with Proper Use of Single Flange Wheels & Trolley Syst

How Can You Reduce Risk in Materials Handling with Proper Use of Single Flange Wheels & Trolley Syst

Single flange wheels and trolley systems are essential for safe, efficient materials handling. When used correctly, they allow smooth load movement, prevent derailment, and minimise accidents. Choosing the right system and using it properly helps protect both workers and equipment from unnecessary risk.

What Are Single Flange Wheels and Trolley Systems?

In lifting and materials handling, single flange wheels and girder trolley systems are key components that enable the controlled movement of loads along a beam or rail.

  • Single flange wheels guide and stabilise the trolley, preventing it from slipping or derailing.
  • Trolley systems support and move suspended loads horizontally, often in combination with a hoist.

Together, they create a safe and stable lifting path, reducing manual strain and ensuring precise positioning of heavy materials.

Single flange wheels provide guidance, while trolleys provide movement.

Why Does Proper Use Matter for Safety?

Improper use or poor-quality girder trolley components are among the leading causes of lifting accidents. A misaligned wheel, overloaded trolley, or uninspected track can quickly result in dropped loads, equipment damage, or worker injury.

The correct use of single flange wheels and girder trolley systems ensures:

  • Even load distribution across the beam
  • Smooth travel and controlled movement of the suspended load
  • Reduced friction and wear on both wheel and beam
  • Improved stability, especially during lifting or stopping

Proper use minimises risk by ensuring smoother, safer, and more predictable load handling.

How Do Single Flange Wheels Work?

Single flange wheels feature one raised edge (or flange) that guides the wheel along the track and prevents lateral movement. The other side of the wheel remains flat to allow for smooth rolling and minor alignment adjustments.

These wheels are commonly found on beam trolleys, gantries, cranes, and rail systems, where they support heavy vertical loads while maintaining horizontal mobility.

Key Features Include:

  • Flanged Edge: Keeps the trolley aligned on the beam
  • Hardened Steel Construction: Provides durability under heavy loads
  • Precision Bearings: Reduce friction for smooth operations
  • Compatibility: Works with both straight and curved beam systems

Single flange wheels keep trolleys safely aligned and running smoothly along their path.

What Are the Main Types of Trolley Systems?

Trolley systems come in several configurations to suit different load capacities and applications.

  • Push Trolleys: Moved manually along the beam; ideal for lighter loads
  • Geared Trolleys: Operated via a hand chain, providing precise control
  • Electric Trolleys: Motor-driven for heavy loads or high-frequency use

Each trolley type uses wheels (often with single flanges) that roll along the beam flange, distributing weight evenly and maintaining stability.

Benefits of Using Trolleys:

  • Enables horizontal movement without manual lifting
  • Allows safe and accurate load positioning
  • Reduces operator fatigue and risk of musculoskeletal injury
  • Supports integration with hoists for vertical lifting

The right trolley type provides safer, smoother load handling and helps prevent accidents.

How Can You Reduce Risk When Using Single Flange Wheels and Trolleys?

Reducing risk requires correct selection, setup, and operation of all trolley components.

1. Choose the Correct Load Capacity

Always ensure that both trolley and wheels are rated for the maximum load they will carry. Exceeding the Working Load Limit (WLL) can lead to wheel deformation or failure.

2. Inspect Before Every Use

Check for signs of wear, corrosion, or misalignment. Pay attention to:

  • Wheel surfaces (look for cracks or flat spots)
  • Bearings (ensure smooth rotation)
  • Beam flanges (check for deformation or debris)

3. Ensure Proper Alignment

Wheels must run true along the beam. Misalignment increases friction and can cause derailment.

4. Maintain a Clean Track

Dirt, grease, or rust on the beam can affect wheel traction. Regular cleaning reduces slip risk and prolongs equipment life.

5. Use Rated Accessories

Always pair your trolley and wheels with tested and certified hoists, slings, and clamps. Mismatched components compromise safety.

Reducing risk starts with correct equipment selection, routine inspection, and careful operation.

What Happens When Equipment Is Used Incorrectly?

Improper use can quickly lead to accidents or costly downtime.

  • Overloading may bend the wheel or cause the trolley to jam
  • Poor alignment can cause derailment or uneven load distribution
  • Lack of maintenance increases wear and the risk of sudden failure

In serious cases, incorrect setup can result in dropped loads or structural damage. These issues are preventable through regular inspections and adherence to manufacturer guidelines.

Most trolley and wheel failure occur due to misuse or neglect. Both of which can be avoided with proper maintenance.

What Are the Benefits of Using Quality Equipment?

High-quality trolley and single flange wheels deliver long-term performance and peace of mind.

Key Benefits:

  • Improved Safety: Reduces likelihood of accidents and dropped loads
  • moother Operation: Bearings and balanced construction ensure precision movement
  • Extended Service Life: Quality components resist wear and corrosion
  • Lower Maintenance Costs: Less downtime and fewer part replacements
  • Compliance: Meets Australian Standards for lifting and materials handling

Certified, high-quality equipment ensures reliability and compliance while lowering operational risks.

Why Choose Bunzl Safety & Lifting for Trolleys and Clamps?

At Bunzl Safety & Lifting, safety and reliability come first. We supply a wide range of tested and certified girder trolley systems and single flange wheels, built to meet the highest industry standards.

Our Range Includes:

  • Push and geared trolleys for precise movement and control
  • Girder clamps and accessories for safe anchoring and load restraintn
  • Replacement wheel sets designed for stability, smooth travel, and long service life

All equipment is tested and certified to Australian Standards, ensuring every component performs safely under load. Our LEEA-trained inspectors and NATA-accredited testing services provide expert support and certification where required.

Bunzl Safety & Lifting provides compliant, high-quality solutions backed by technical expertise and nationwide support.

Safe Handling Starts with the Right Equipment

Reducing risk in material handling begins with selecting the right trolley system and wheel design. Proper use of single flange wheels ensures stable travel, while well-maintained trolleys provide controlled, secure movement.

When you invest in tested, certified equipment from Bunzl Safety & Lifting, you’re not just buying components; you’re investing in safety, compliance, and performance.

Explore our full range of trolleys and clamps or contact our team for expert advice on choosing the right system for your lifting operation.

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About Bunzl Safety and Lifting

Bunzl Safety and Lifting offers an integrated approach to the selection, supply, service, and replacement of safety products, resulting in our ability to manage the complete life cycle of your personal and workplace safety requirements. Bunzl Safety and Lifting is a leading manufacturer of safety products, we provide the very best in workwear, corporate wear, PPE, footwear, materials handling, load restraint, and recovery,height safety, and site safety. We are also a leading supplier of some of the best industrial safety brands on the market, including Mack, Ninja, Contego, Boomerang, Beaver, B-Safe, WS Workwear, Frontier, Black Rat, Robertsons, 3M, Honeywell, Ansell, Bolle Safety, DuPont, Donaghys, MSA, Moldex, Steel Blue, Oliver, uvex, Sqwincher, MaxiFlex, DNC Workwear, Mayo Hardware, Gunnebo Industries, Skylotech and Blundstone. We also offer a range of services including product specialisation and consolidation, custom embroidery and branding, lifting equipment and inspections, NATA Accredited testing and services, height safety installed systems and training, managed inventory, eCommerce and digital solutions, clothing fitouts and yearly uniform issues, ethical sourcing, Indigenous Engagement, and environmental responsibility. We have an Australia-wide network of branches that ensures fast shipping across the country.

Bunzl Brands & Operations Pty Ltd (BBO) located at 55 Sarah Andrews Close Erskine Park NSW 2579 quality scope covers: manufacturing, importing, wholesaling, repairing and testing of lifting, rigging equipment, winches, hoists and materials handling products. The manufacture of synthetic slings and webbing products including load restraint and height safety equipment. Manufacture, import, wholesale and distribution of PPE products, workwear and hand tools. Design and development of products and services and the provision of mechanical testing services.