Sizing - Do some simple sums
G'day Dan,
While your stated intention is to have a sectional layout on casters that you can roll around to get at cellar walls etc later as required, remember that one of the advantages of a modular/sectional build methodology as outlined under TOMA principles, is the ability to do stuff like this to get at wiring etc in the construction phase.
Using lightweight construction techniques I can move and flip this 4'3" long module by myself. It weighs in at under 40lb fully sceniced. So I can work with a linear weight of about 10lb//' of modular length. If you have an additional person to help with this type of stuff, then that's good. But If you don't...
Now remember also I'm using these tables as layout support. I don't have heavy leg structures attached to the module frame and top. As stated, your aim is to be able to roll your modules on casters. This implies a reasonably heavy set of legs for rigidity and on which to mount the casters. So you will be unable to match my modular weight/' once the legs become semi-permanently attached to the module top and frame. So let's assume you permanently attach your legs after you have the track down and have any "flipping" necessary to attach wiring/point motors etc already done. Let's have a look at your basic module top and 4"x1" framing proposed in your original post. Here comes the sums...
For a 4' long module, assuming 1 transverse brace placed "centrally" (can be moved a few inches either way to dodge point motors etc) Your real rigidity is in the 1/2" thick ply. top.
using the plywood weight calculator at http://theplywood.com/weight and white/yellow pine ply
1/2"plywood top - 4' by 2' = 7 lb
Module framing at 0.64lb//' from https://www.engineeringtoolbox.com/structural-lumber-properties-d_1835.html
2 longitudinal stringers - 4' long x 4"x1" = 2 x 4 x 0.64 = 5.12 - call it 5lb
3 transverse stringers- 2' long x 4'" x1" = 3 x 2 x 0,64 = 3.94lb - call it 4lb
Total module weight = 16lb for a bare module top
For a 8' long module assuming 1 transverse brace placed every 2' (can be moved a few inches to dodge point motors, etc)
Using 2 4' by 2' 1/2 tops = 2 X 7 - 14lb
2 longitudinal stringers - 8' long x 4"x 1" = 2 x 8 x 0.64 = 10.24lb call it 10lb
5 transverse stringers - 2' long x 4'" x1" = 5 x 2 x 0,64 = 6.4lb - call it 7lb
Total module weight = 31lb for a bare module top
You'd want to have 2 persons available to flip ths 8' long module for wiring work at a bench, Realistically you are looking at about 5/lb for each foot of module without including the weight of any support structure, track or scenery. Any of these can rapidly add weight to a module. I'd be recommending shorter modules just based on these basic sums. Even with 4' modules, if there is any lifting or flipping to be done rather than rolling, I'd be getting a second person to assist.
I can just move my 40 lb 4'3" x 2' module by myself if I have to lift it rather than skid it from one table to another. Please have a look at my responses on Page 2 and 3 at https://forum.mrhmag.com/post/toma-ideas-in-practice-12207107 especially at the "awkwardness factor", There is also some other stuff in that thread that might be relevant for you,