Air Skates: How to Move Multi Ton Loads Without Touching the Floor

Air skates, also known as air casters, air skids, or air dollies, are a specialized rigging solution that R. Baker & Son has deployed for many years to move heavy machinery, fragile equipment, and multi-ton loads inside buildings. These systems range in capacity from approximately 12 to 150+ tons, depending on configuration. Using hovercraft technology, we float equipment with omnidirectional movement on a thin cushion of air across flat, smooth surfaces with zero floor damage and minimal effort. For plant relocations, renovations, and new construction projects where traditional methods risk epoxy floors, polished concrete, or tight spaces, air skates are often the only practical option - and our teams know exactly how to make them perform.

On renovations, new construction projects, and plant relocations, R. Baker & Son has mastered the use of air casters to move and precisely position heavy machinery and process equipment where traditional methods simply aren't an option.

On one memorable project, the plant owner was skeptical, even calling it crazy, when R. Baker proposed moving heavy equipment across brand-new epoxy floors. To his amazement, every piece of equipment glided across the floor on air skates without leaving so much as a scratch. Just a few dusty footprints that wiped away easily.

How Do Air Skates Work? Air skates operate on the principle of total force, which is different from pressure alone. A 24-inch circular disc has approximately 452 square inches of surface area. At just 30 PSI, that translates to over 13,500 pounds of lifting force per skate, or more than 54,000 pounds when using four skates together, all while maintaining that same 30 PSI.

This lifting force, when properly distributed across multiple skates, allows us to safely float loads up to 100 tons while maintaining the same low PSI.

Low-profile caster modules are placed at strategic support points beneath the load to evenly distribute weight. Compressed air inflates urethane diaphragms that lift the load off the floor. Air escapes between the floor and the diaphragms in a controlled manner, and the load begins to float.

Because air casters are omnidirectional and nearly friction-free, a single person or small crew can move thousands of pounds with minimal effort, complete control, and no damage to flooring. They also allow for easy, precise positioning, even in confined spaces. If floors aren't completely smooth or loads need to cross transitional areas, overlay materials like sheet metal or heavy-gauge plastic can be used to create an even surface beneath the skates.

Air Skates vs. Omnidirectional Nylon Skates It's worth noting that R. Baker & Son frequently combines air skates with other equipment-moving methods, including omnidirectional nylon skates, depending on what the job requires. No two projects are alike.

Many common flooring systems, including polished concrete, sealed concrete, epoxy, terrazzo, and other smooth surfaces, are ideal for both systems. The right choice depends on load weight, floor condition, space constraints, and project timeline - something our experienced teams assess on every job.

One thing is consistent, though: whenever air skates are in use, there's always a crowd watching in disbelief.

When to Choose Air Skates (and When We Combine Them With Other Methods) Air skates shine in situations where floor protection is paramount and precise positioning is required. They are ideal for: • Sensitive flooring like new epoxy, polished concrete, or terrazzo • Confined spaces where traditional cranes or forklifts won’t fit • Projects demanding millimeter-level accuracy

Our teams often combine air skates with omnidirectional nylon skates or other rigging tools based on the specific load, floor conditions, and schedule. This flexible approach ensures the safest, most efficient solution every time.

Safety & Best Practices From 90+ Years of Rigging At R. Baker & Son, safety is built into every step. Our best practices include: • Thorough pre-move floor assessments and custom overlay planning • Precise air supply and pressure management to maintain stability • Deployment by experienced riggers and millwrights with decades of hands-on expertise

This attention to detail protects both your equipment and your facility.

Why Experience Matters At R. Baker & Son, success with air skates comes from more than having the equipment - it comes from many years of real-world application on complex plant moves, renovations, and precision positioning projects. Our teams have refined every aspect - from initial load distribution and floor assessment to final placement - so your equipment is protected, your schedule stays on track, and your floors remain pristine. We are committed to providing our clients with the newest technologies and safe and cost effective solutions. While maintaining the quality and personal care your projects deserve.

R. Baker & Son: Over 90 Years of Rigging Expertise R. Baker & Son brings more than 90 years of rigging, millwright, and plant relocation expertise to every job. Our teams have a talent for finding the most innovative and efficient ways to get your equipment where it needs to go, safely and on schedule. Beyond the move itself, our Rigger and Millwright teams can also fully assemble and commission equipment, getting it ready for operation from day one.

Ready to move heavy equipment the smart way? Contact R. Baker & Son today.

R. Baker & Son - Rigging & Demoliton Contractors
190 Boundary Road
Marlboro, NJ 07746
732-222-3553

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