Panel Carts: A Buying Guide for Material Handling Professionals

Panel carts are specialized material handling equipment (MHE) designed to move large, flat items like sheets of wood, metal, glass, or plastic. They’re not complicated equipment: Most consist of a vertical frame with a flat or tilted base, with a series of supports to keep the load secured during movement.

If your operation handles large, flat materials (in other words, panels of any kind), panel carts can help you limit material loss and improve efficiency. Solus Group carries ergonomically engineered BHS Panel Carts (PC) designed for the job. 

Panel carts provide:

• Better efficiency and productivity by streamlining material movement.
• Enhanced workplace safety by minimizing manual lifting and carrying.
• Reduced material damage by securely transporting delicate materials, preventing scratches, dents, and breakage.
• Ergonomic benefits that promote better posture and reduce physical strain on workers.

As is the case with virtually all MHE, panel carts can be customized to meet your needs. Call our sales team at 314-696-0200 to discuss customization options or read on to learn how to find the right carts for your application. 

Panel Carts: Use Cases and Common Materials

So, if panel carts are so useful, why haven’t you heard of them? Probably because you know them by a different name. 

Panel carts are common in virtually every industry, and they’re often nicknamed for the products they’re associated with:

• Construction: Panel carts are used for transporting drywall, plywood, paneling, and other building materials on job sites. They’re sometimes referred to as drywall carts or simply as material carts. 
• Manufacturing: Manufacturers might refer to sheet good carts, as the equipment is frequently used to move sheet metal, large components, and finished goods within factories.
• Warehousing: Carts are essential for efficiently storing and retrieving large items in inventory. They may be called vertical panel carts or material carts.  
• Retail: In retail applications, panel carts are used for handling large displays, signage, and furniture. They may be referred to as panel dollies (somewhat incorrectly, since “dollies" and “carts" are different equipment). 

While panel carts are often associated with drywall, plywood, MDF, and other building materials, they’re equally capable of moving plastic, glass, metal, and insulation. 

The design of the cart may change somewhat to accommodate different types of loads. For example, some carts may have padding or extra supports to protect glass and other fragile materials.

Panel Carts vs. Flat Deck Carts

Solus Group also carries Flat Deck Carts, which are an obvious alternative to panel carts — but if you’re moving large, flat materials, there’s really no substitute. 

By orienting materials vertically, you keep products protected and reinforce good ergonomic habits. Workers won’t have to bend as frequently when handling the materials, which helps to reduce the risk of musculoskeletal injuries. 
Choose a Flat Deck Cart (FDC) over a panel cart when you need to move heavier or bulkier items with dimensions that won’t fit on a panel cart. FDCs are also preferable if you need forklift compatibility (panel carts typically don’t have integrated fork pockets). 

Choosing the Right Panel Cart: Factors to Consider

Once again, panel carts aren’t particularly complex — but you’ll still need to research your options to find equipment that works for your application. 

Factors to consider: 

Capacity and Weight Limits: This is simply the maximum weight the cart can handle when fully loaded. Industrial panel carts should be rated for around 1,000 lbs. 

Size and Dimensions: Consider the dimensions of the materials being transported and the available space for maneuvering the cart. Measure both the materials and the intended pathways to ensure a proper fit.

Construction Materials and Durability: Choose a cart made from robust materials like steel or aluminum for long-term use. Look for features that enhance durability, such as powder-coated finishes for rust and scratch resistance.

Maneuverability: Look for carts with high-quality casters that swivel easily and provide smooth movement. Consider the type of caster (rigid or swivel) and their size for optimal performance on different surfaces.

Safety Features: Ensure the cart has brakes to secure it in place and edge protection to prevent materials from sliding off. Additional safety features might include ergonomic handles and securement straps.

Selecting the right panel cart involves careful consideration of these factors to ensure it aligns with your specific needs and operational requirements. 

Products to Consider: BHS Panel Cart (PC)

For a reliable and versatile option, consider the BHS Panel Cart (PC) offered by Solus Group. This cart is designed for transporting a variety of materials, including drywall, plywood, folding tables, and more. It features a heavy-duty steel frame with a carpeted plywood deck to protect loads from damage. 

With a capacity of 1,000 lbs (454 kg) and removable handles for easy loading and unloading, the BHS Panel Cart offers a durable and efficient solution for your material handling needs.

Standards and Regulations for Panel Carts

The Occupational Safety and Health Administration (OSHA) does not specifically require the use of panel carts, though the General Duty Clause requires employers to provide a safe work environment. 

Since heavy panels present serious ergonomic risks, panel carts can improve compliance. According to OSHA, "Poor workplace design leads to fatigued, frustrated, and hurting workers who are less productive and more prone to injury." Incorporating ergonomic principles in material handling equipment like panel carts can significantly reduce the risk of musculoskeletal disorders and improve worker well-being.

Broadly speaking, vertical material carts can also aid in compliance with the general materials handling and storage standards (29 CFR 1910.176) by preventing trip & fall hazards. 

To learn more about the benefits of an ergonomic workplace, read: The Productivity Benefits of Ergonomics in 4 Statistics

Custom Panel Cart Solutions from Solus Group

Solus Group specializes in providing custom material handling equipment, including panel carts tailored to specific needs. We work with our manufacturers to design carts with unique dimensions, weight capacities, and features to optimize your material handling processes.

Whether you need to handle larger vertical materials or navigate around tighter-than-average corners, we’re here to help.  Call 314-696-0200 to speak with an expert.

Vertical Material Carts: Frequently Asked Questions (FAQ)

What are the weight limits of panel carts?

Most industrial panel carts are rated for around 1,000 lbs. The BHS Panel Cart (PC) has a capacity of 1,000 lbs (454 kg).

What are the standard dimensions of panel carts?

Standard dimensions vary. Consider the size of the materials you'll be transporting and the space available to maneuver the cart. The BHS Panel Cart is 30" W by 60" L, but additional lengths and widths are available as standard models; the cart can also be customized to fit your specific needs.

What are the different types of casters available on panel carts?

Panel carts should use high-quality casters that swivel easily for smooth movement. The type of caster (rigid or swivel) and their size will impact performance on different surfaces. The BHS Panel Cart features four 6-inch casters, with two swivel and two rigid casters for optimal maneuverability.

What is the warranty on a BHS Panel Cart?

BHS offers a 13-month warranty against defective parts and workmanship on all of their products, including the Panel Cart.

Can panel carts be used outdoors?

While panel carts are primarily designed for indoor use, they can be used outdoors in some cases. Consider the caster type and surface conditions for optimal performance.

Are panel carts forklift compatible?

Panel carts typically don't have integrated fork pockets, making them less suitable for forklift use. If you require forklift compatibility, consider a Flat Deck Cart (FDC).

What is the difference between a panel cart and a dolly?

Panel carts are designed to transport large, flat items vertically, while dollies are typically used for moving smaller items or boxes horizontally. Panel carts offer better protection and ergonomics for handling panels.

Find the perfect material handling solutions for your operation. Call 314-696-0200 to speak with a member of our sales team.