Earthmoving Tyre Safety - LC Tyres

Earthmover Tyre Damage
Information Booklet
Produced by LC Tyres
LC Tyres
22 Ballymount Rd
Dublin
01 4050 135
FOREWORD
The Health and Safety Authority encourages and welcomes industry guidance such as this
produced by LC Tyres.
Tyre failure either during the operation of mobile equipment or during maintenance
activities such as inflation or replacement of tyres has resulted in a number of serious and
fatal accidents.
If systems are in place to examine tyres at regular intervals and maintenance is planned
and where necessary carried out by competent operatives, using equipment that is suitable
then accidents can be prevented.
I am pleased to acknowledge the work of the LC Tyres and particularly Tony Davenport in
preparing this guidance. It brings together best practice in the inspection and maintenance
of tyres on heavy mobile plant and has the interest of those involved in the operation or
maintenance of these vehicles at heart.
It is only by taking ownership of the management of risk that improvements will be made,
and I commend the use of this guidance to all concerned.
Pat Griffin
Senior Inspector Agriculture, Mines and Quarries

Health and Safety Authority
LC Tyres
22 Ballymount Rd
Dublin
01 4050 135
INDEX
Click on any title to link to page
Section Sub-Section Page Section Sub-Section Page

Bead Failure Tread Damage
Guide Guide
Bead Blisters 1 Tread Cut Separation 31
Bead Cuts 2 Tread Cut 32
Bead Rocking/Wear 3 Chunking 33
Bead Rupture/Bursting 4 Mismatching 34
Electrical Contact Damage 5 Tread Separation 35
Irregular Bead Contact Area 6 Worn Out 36
Irregular Handling Damage 7 Tread Flaking/Chipping 37
Bead Chafer Separation 8 Lug Tear 38
Bead Split 9 Spin Cuts 39
Fitting Damage 10 Tread Penetration 40
Bead Cracks 11 Uneven Tread Wear 41
Shoulder Delamination 42
Damage Guide
Shoulder Cut 12 Tread Repair Failure 43
Shoulder Belt Separation 13 Tread Impact 44
Shoulder Lug Tear 14 Electrical Contact 45
Damage
Uneven Shoulder Wear 15 Stress Cracks 46
Foreign Object Damage 16 Spot Wear 47
Shoulder Impact 17
Mechanical Damage 18
Shoulder Penetration 19
Sidewall General Tyre
Damage Guide Advice Guide
Sidewall Bubbles 20 Tyre Inflation Inflating & Re-Inflating 48
48-55 Tyres
Lateral or Radial Cracks 21 Inspection 49
Mechanical Damage 22 Suitable Restraining 50
Devices
Sidewall Penetration 23 Restraining The 51
Assembly
Repair Failure 24 The Trajectory Zone 52
Loose or Cracked Repair 25 Monitoring The 53 - 55
Inflation Process
Circumferential Cracks 26 Inflation Maintenance 56
Sidewall Cut 27 Excessive Heat 57
Turn-Up Ply 28 Electrical Contact 58
Separation/Zipper
Run Flat 29 Chemical Degradation 59
Duals Rubbing 30 Hazardous Pressure 60
Obvious Irregularities 61
LC Tyres
22 Ballymount Rd
Dublin
01 4050 135
Bead Failure Guide
Bead Blisters
Definition:
Swelling or bulging in the flange contact area caused by friction.
Contributing Factors:
1. Poor underfoot conditions, undulations.
2. Incorrect or defective rim components.
3. Improper inflation or overloading.
4. Excessive torque, cornering or rim spin.
Process Map
Important Notes:
1. Bead blisters are usually the first warning signs of incorrect/defective rim components; this
should be rectified before further damage is incurred.
2. Bead damage with exposed cords is irreparable.
LC Tyres
22 Ballymount Rd
Dublin 01 4050 135 Page 1
Bead Cuts
Definition:
Cut by a foreign object in the bead area.
1. Defective flange.
2. Poor housekeeping, fitment/handling damage.
3. Foreign object embedded between the bead and flange.
4. Operational conditions.
Process Map
Important Notes:
1. Cosmetic repair is advisable before the cords are exposed.
LC Tyres
22 Ballymount Rd
Bead Rocking/Wear
Definition:
Excessive wear on the bead base or bead support area caused by friction.
1. Poor underfoot conditions or undulations.
Process Map
Important Notes:
1. Rim inspection is critical before a tyre is refitted to the rim.
LC Tyres
22 Ballymount Rd
Bead Rupture/Bursting
Definition:
Bead wires exposed from separation of the rubber around the bead bundle.
1. Abnormal heat generated from the brake drums.
4. Electrical discharge.
Process Map
There is no process other than to scrap the tyre
Important Notes:
1. Bead rupture is irreparable.
LC Tyres
22 Ballymount Rd
Electrical Contact Damage
Definition:
Small diameter holes in the rubber on the base of the bead.
Electrical discharge from lightning, or contact with high tension wires.
Process Map
Important Notes:
1. Do-not enter the flash area if the machine is still in contact with any power sources.
2. Any contact by a machine with an electrical power source, must be reported so an inspection
can be carried out to ensure the machine is still safe to use.
LC Tyres
22 Ballymount Rd
Irregular Bead Contact Area
Definition:
Base of the bead is deformed.
1. Incorrect fitment of centring of the tyre on the rim.
3. Insufficient lubricant when fitting the tyre.
4. Incorrect rim/tyre matching.
Process Map
Important Notes:
1. Decreased bead contact increases the risk of uncontrolled tyre deflation.
LC Tyres
22 Ballymount Rd
Irregular Handling Damage
Definition:
Damage or deformation to the bead area, due to incorrect handling.
1. Incorrect or defective handling equipment or methods.
2. Lack of tyre handling skills.
3. Peer pressure.
4. Negligence or abuse.
Process Map
Important Notes:
1. Follow the correct tyre handling procedures as recommend by the tyre manufacturers.
LC Tyres
22 Ballymount Rd
Bead Chafer Separation
Definition:
Separation starting from the edge of the chafer, due to fatigue.
1. Improper tyre seating.
4. Scuffing from fast cornering.
Process Map
Important Notes:
1. Bead separation usually results from bead rocking/wear.

2. Bead separation is irreparable.
LC Tyres
22 Ballymount Rd
Bead Split
Definition:
Cracks in the centre of the bead.
1. High torque or rim spin.
2. Incorrect or defective rim components/drive lock.
4. Incorrect fitment.
Process Map
Important Notes:
1. Never mix rim components from different manufacturers.
LC Tyres
22 Ballymount Rd
Fitting Damage
Definition:
Damage to the bead area during fitment.
1. High torque or rim spin.
4. Incorrect fitment.
Process Map
Important Notes:
1. Correct bead lubrication is critical to correct and successful fitment.

2. Over lubrication of the bead can result in rim spin and/or O Ring ejection.
LC Tyres
22 Ballymount Rd
Dublin 01 4050 135 Page 10
Bead Cracks
Definition:
Diagonal crack around the bead support area.
1. Poor underfoot conditions, undulations.
Process Map
Important Notes:
1. Cosmetic repair is advisable before the cords are exposed
LC Tyres
22 Ballymount Rd
Dublin 01 4050 135 Page 11
Shoulder Damage Guide
Shoulder Cut
Definition:
A cut in the shoulder area, but not damaging the casing.
1. Spillage and foreign objects.

2. Course material on the berm/windrow.
3. Poor pit conditions.
4. Aggravated by water.
Process Map
Important Notes:
1. Carry out repairs as soon as possible to prevent the damage from getting worse.
LC Tyres
22 Ballymount Rd
Dublin 01 4050 135 Page 12
Shoulder Belt Separation
Definition:
Separation of the crown plies from the casing plies in the shoulder area causing cracks of deformation of
the shoulder.
1. Heat, excessive cornering, speeding and exceeding the TKPH of the tyre.
2. Improper inflation, overloading or an impact.
3. Poor site conditions.
Process Map
Important Notes:
1. Shoulder belt separation is irreparable.
LC Tyres
22 Ballymount Rd
Dublin 01 4050 135 Page 13
Shoulder Lug Tear
Definition:
Shoulder lug torn away from the sidewall or tread by an external force.
1. High speeds, hair pins, sharp cornering or wheel spinning.

2. Improper inflation, overloading or abrasive conditions.
3. Driving or reversing onto the tip wall, windrow or berm.
Process Map
Important Notes:
1. Carry out repairs as soon as possible to prevent the damage from getting worse.
LC Tyres
22 Ballymount Rd
Dublin 01 4050 135 Page 14
Uneven Shoulder Wear
Definition:
Uneven or increasing wear from the shoulder to the tread.
1. High speed cornering, hard braking or rapid acceleration.

2. Improper inflation, overloading or improper tyre matching.
3. Faulty suspension or wheel alignment.
Process Map
Important Notes:
1. The reason for uneven wear must be investigated and rectified.
LC Tyres
22 Ballymount Rd
Dublin 01 4050 135 Page 15
Foreign Object Damage
Definition:
Damage to the shoulder area due to external factors.
1. Machine defects, rock ejector damage or Grader blade.

2. Accident damage or vehicle recovery.
3. Foreign object strike between dual fitted tyres.
Process Map
Important Notes:
1. The reason for the damage needs to be investigated and rectified.
LC Tyres
22 Ballymount Rd
Dublin 01 4050 135 Page 16
Shoulder Impact
Definition:
External damage to the shoulder casing causing destructive damage to the protection plies and casing.
1. Poor underfoot conditions, spillage, water, potholes or undulations.
2. Improper inflation.
3. Speed verses road conditions.
4. Driving habits, negligence or overloading.
Process Map
Important Notes:
1. Shoulder impact is irreparable.
LC Tyres
22 Ballymount Rd
Dublin 01 4050 135 Page 17
Mechanical Damage
Definition:
Damage to the shoulder area by the external machine structure.
1. Equipment defects or rock ejector damage.

3. Movable machine parts, for example, Grader blade, bucket pins etc.
Process Map
Important Notes:
1. Tyres with damage should be fitted to dual wheel assemblies, with the damage or repair
facing inwards.
LC Tyres
22 Ballymount Rd
Dublin 01 4050 135 Page 18
Shoulder Penetration
Definition:
Cuts which penetrate through the casing in the shoulder area.
1. Poor housekeeping or road conditions.

2. Driver abuse, negligence or deviation from an authorised route.
3. Foreign objects in the working area.
Process Map
Important Notes:
1. Once the cords are exposed, then a repair should be carried out as soon as possible.
LC Tyres
22 Ballymount Rd
Dublin 01 4050 135 Page 19
Sidewall Damage Guide
Sidewall Bubbles
Definition:
Swelling or deformation to the sidewall caused by broken cords in the casing structure or inner liner
damage.
1. Improper inflation or loading.

2. Manufacturing defect in the casing construction causing the sidewall cords to be unevenly spaced.
3. Poor underfoot conditions.
4. Excessive sidewall flexing, undulations potholes or high speed cornering.
Process Map
Important Notes:
1. Cosmetic repair is advisable before the cords are exposed

LC Tyres
22 Ballymount Rd
Dublin 01 4050 135 Page 20
Lateral or Radial Cracks
Definition:
Cracking or tearing in the sidewall.
1. Undulations or excessive stress.

2. Under inflation or overloading.
Process Map
Important Notes:
1. Cosmetic repair is advisable before the cords are exposed.
LC Tyres
22 Ballymount Rd
Dublin 01 4050 135 Page 21
Mechanical Damage
Definition:
Damage to the shoulder area by the external machine structure.
1. Equipment defects or rock ejector damage.

3. Movable machine parts, for example, Grader blade, bucket pins etc.
Process Map
Important Notes:
1. Tyres with damage should be fitted to dual wheel assemblies, with the damage or repair
facing inwards.
LC Tyres
22 Ballymount Rd
Dublin 01 4050 135 Page 22
Sidewall Penetration
Definition:
Cuts in the sidewall that reach or go through the inner liner.
1. Sharp objects in the work area or spillage.

2. Rocks caught between dual fitted tyres.
3. Operator negligence.
4. Excessive flexing of the sidewall due to overloading.
Process Map
Important Notes:
1. Once the cords are exposed, a repair should be carried out as soon as possible.
LC Tyres
22 Ballymount Rd
Dublin 01 4050 135 Page 23
Repair Failure
Definition:
Pressure loss at the site of a repair.

2. Operating conditions, water or undulations.
3. Repair defect.
4. Repair outside recommended specifications.
5. Poor workmanship.
6. Secondary damage to the repair.
Process Map
Important Notes:
1. Repaired areas are more prone to secondary damage.
LC Tyres
22 Ballymount Rd
Dublin 01 4050 135 Page 24
Loose or Cracked Repair
Definition:
A repair that shows signs of a possible failure occurring.

2. Bad operating conditions, water or undulations.
3. Repair defect.
Process Map
Process Map
Important Notes:
1. Repaired areas are more prone to secondary damage.
LC Tyres
22 Ballymount Rd
Dublin 01 4050 135 Page 25
Circumferential Cracks
Definition:
Lateral splitting at the rubber juncture (where the shoulder and sidewall meet
1. Excessive stress.
3. Operating conditions, undulations.
4. Sharp cornering.
5. Manufacturing defect.
Process Map
Important Notes:
1. Once the cords are exposed, a repair should be carried out as soon as possible.
LC Tyres
22 Ballymount Rd
Dublin 01 4050 135 Page 26
Sidewall Cut
Definition:
A cut observed in the sidewall, but not penetrating the casing.
1. Sharp objects in the work area.

2. Rocks caught between the dual wheels.
3. Operator negligence.
4. Under inflation or overloading.
5. Poor underfoot conditions or water.
Process Map
Important Notes:
1. Bead separation usually results from bead rocking/wear.

2. Bead separation is irreparable.
LC Tyres
22 Ballymount Rd
Dublin 01 4050 135 Page 27
Turn-Up Ply Separation/Zipper
Definition:
Separation occurring from the end of the casing cords due to fatigue.
1. Improper inflation or mounting.
2. Overloading, excessive braking or speeding.
3. Scuffing form sharp cornering.
4. Manufacturing defect.
Process Map
Important Notes:
1. This only relates to radial tyres.
LC Tyres
22 Ballymount Rd
Dublin 01 4050 135 Page 28
Run Flat
Definition:
Destruction of the casing caused by driving with no air in the tyre.
1. Impact of penetration.
2. Valve, O Ring or rim failure.
 Ring ejection.
3. Poor pressure maintenance.
Process Map
Important Notes:
1. Inflation procedures must always be followed.

2. Low pressure can cause the tyre to overheat.
LC Tyres
22 Ballymount Rd
Dublin 01 4050 135 Page 29
Duals Rubbing
Definition:
Signs of friction on the inner walls of dual tyres.
1. Under inflation, mismatching or incorrect dual spacing.
2. Overloading, off centre loading or undulations.
3. Suspension defects.
Process Map
Important Notes:
1. Dual tyres rubbing, produces friction and heat.

2. Wider tyres require wider rims, to change specifications, always seek manufacturer’s advice.
LC Tyres
22 Ballymount Rd
Dublin 01 4050 135 Page 30
Tread Damage Guide
Tread Cut Separation
Definition:
Separation caused by cuts on the tread crown area.
1. Improper inflation or underfoot conditions.

3. Over loading or speeding.
4. Spinning, skidding or sliding.
Process Map
Important Notes:
1. Separations are irreparable.
LC Tyres
22 Ballymount Rd
Dublin 01 4050 135 Page 31
Tread Cut
Definition:
Cut in the tread crown, but not penetrating the casing.

3. Foreign objects in the work area.
4. Spinning, skidding or sliding.
Process Map
Important Notes:
1. Tread cut can be repaired.

2. Tread cuts not repaired, could result in tread separation.
LC Tyres
22 Ballymount Rd
Dublin 01 4050 135 Page 32
Chunking
Definition:
Chunks of tread partially or completely torn off.

2. Excessive speeding or aggressive braking.
3. Overloading.
4. Mismatched diameters on dual tyre machines.
5. Spinning, skidding or high torque.
Process Map
Important Notes:
1. If it is close to the end of its tread life, it is not recommend using chunked tyres for
retreading.
2. Chunking is not repairable.
LC Tyres
22 Ballymount Rd
Dublin 01 4050 135 Page 33
Mismatching
Definition:
Fitting of tyres causing a mismatch of brand, diameter, size or application.
1. Lack of supervision.
2. Lack of suitable tyres.
3. Lack of knowledge or experience.
Process Map
Important Notes:
1. Loader variance – front to rear 4%, left to right 3%.

2. Haul machines 10% difference on duals, 3% left to right.
LC Tyres
22 Ballymount Rd
Dublin 01 4050 135 Page 34
Tread Separation
Definition:
Deformation of the tread area due to the tread band separating from the casing ply.
1. Excessive heat generation.

2. Exceeding the TKPH for the tyres.
3. Excessive cornering.
4. Incorrect inflation or speed.
5. Overloading.
Process Map
Important Notes:
1. Tread separation is irreparable.
LC Tyres
22 Ballymount Rd
Dublin 01 4050 135 Page 35
Worn Out
Definition:
Normal wear resulting from on or beyond the bottom of the tread grooves.

2. Bad operating conditions, water or undulations.
3. Repair defect.
Process Map
Important Notes:
1. A lower rolling resistance increases tread life and extends the life of the tyre.
2. Percentage of tread worn does not affect traction ability.
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22 Ballymount Rd
Dublin 01 4050 135 Page 36
Tread Flaking/Chipping
Definition:
The tread breaks off with the appearance of fish scales, usually throughout the surface of the tread crown.
1. Fatigue in the tread rubber due to bad underfoot conditions.

2. Over inflation.
3. Incorrect tyre specifications.
4. Overloading.
5. Improper braking.
6. Abrasive road surfaces.
Process Map
Important Notes:
1. Flaking is not classed as a removal reason, and does not pose a risk of tyre failure.
LC Tyres
22 Ballymount Rd
Dublin 01 4050 135 Page 37
Lug Tear
Definition:
Ribs, lugs or blocks torn off by external force.
1. Improper inflation maintenance.

2. Excessive loading.
3. Driving over/onto curbs and walls at tipping areas.
4. Turning sharply.
5. Harsh braking.
6. Stone retention.
7. High torque on steep gradients
8. Wheel spinning.
Process Map
Important Notes:
1. A repair can be done to prevent possible separation.

2. Ensure that the repair is done using a patch for strength.
LC Tyres
22 Ballymount Rd
Dublin 01 4050 135 Page 38
Spin Cuts
Definition:
Circumferential cuts or scratches on the tread area, but not penetrating the casing.
1. Spinning due to loss of traction.

2. Spillages.
3. Sharp foreign objects. Aggravated by water.
Process Map
Important Notes:
1. Percentage of tread worn does not affect traction ability.
LC Tyres
22 Ballymount Rd
Dublin 01 4050 135 Page 39
Tread Penetration
Definition:
Cut in the tread reaching through or penetrating the inner liner.
1. Over inflation.
2. Foreign objects.
3. Stone retention.
4. Bad operator practices.
5. Aggravated by water
6. Bad housekeeping.
Process Map
Important Notes:
1. Only remove foreign objects that have penetrated the tyre after the tyre has been deflated.
2. Stones trapped between the tread lugs, can be safely removed with the tyre still inflated, as
long as they have not penetrated the casing at any point.
LC Tyres
22 Ballymount Rd
Dublin 01 4050 135 Page 40
Uneven Tread Wear
Definition:
Uneven wear on the tread area as follows:

 Conical Wear – Both shoulders wear symmetrically quicker.
 Centre Wear – Wear increases shoulder to crown.
 Irregular Wear – Wear increases from one shoulder to the other.
 Heal & Toe Wear – Wear increases on one part of the lug.
1. Improper inflation maintenance.

2. Road cambers.
3. Mechanical defects.
4. Improper tyre or rim matching.
Process Map
Important Notes:
1. Main contributing factors are mechanical defects, but also:

 Centre wear, over inflation, conical wear; suspension/under inflation & Heel/Toe, under
inflation, harsh braking/acceleration or incorrect dual matching.
LC Tyres
22 Ballymount Rd
Dublin 01 4050 135 Page 41
Delamination
Definition:
Separation between layers of rubber.
1. Heat generated through exceeding the tyres TKPH.

2. Loss of adhesion between the compounds in the tread.
3. Manufactures defect.
Process Map
Important Notes:
1. The surface of separated layers of rubber will be smooth.

2. Separated tyres cannot normally be repaired.
LC Tyres
22 Ballymount Rd
Dublin 01 4050 135 Page 42
Tread Repair Failure
Definition:
Pressure loss at the site of the repair.
1. Improper inflation.
2. Poor housekeeping.
3. Overloading.
4. Exceeding the tyres TKPH.
5. Repair defect.
Process Map
Important Notes:
1. Repaired tyres should only to be fitted on the rear of machines.
LC Tyres
22 Ballymount Rd
Dublin 01 4050 135 Page 43
Tread Impact
Definition:
External damage to the tread causing destructive damage to the protective plies and casing.

3. Over inflation.
4. Speed verses site conditions.
5. Over loading.
6. Bad operating practices.
Process Map
Important Notes:
1. Tread impact fractures are irreparable.
LC Tyres
22 Ballymount Rd
Dublin 01 4050 135 Page 44
Electrical Contact Damage
Definition:
Small diameter holes are visible between the lugs on the tread.
Contact either direct or indirect with a power source, for example power lines.
Process Map
Important Notes:
1. Do-not enter the flash area if the machine is still in contact with any power sources.
2. Any contact by a machine with an electrical power source, must be reported so an inspection
can be carried out to ensure the machine is still safe to use.
LC Tyres
22 Ballymount Rd
Dublin 01 4050 135 Page 45
Stress Cracks
Definition:
Cracks visible between the tread lugs but not at the lug base.
1. Under inflation.
2. Over loading.
3. Stone retention.
4. High torque.
5. Steep inclines.
Process Map
Important Notes:
1. Stone retention cracks can normally be repaired.

2. If there are multiple cracks across the tyre, it is not recommended to have it repaired.
LC Tyres
22 Ballymount Rd
Dublin 01 4050 135 Page 46
Spot Wear
Definition:
Increased wear in one or more areas.
1. Mismatching of tyres.
2. Locked or excessive use of brakes.
3. Tyre bouncing caused by faulty suspension of undulations.
4. Poor bead seating caused by bad fitment.
Process Map
Important Notes:
1. Spot wear tyres can normally be repaired if removed before the damage is too great.
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22 Ballymount Rd
Dublin 01 4050 135 Page 47
General Tyre Advice Guide
Inflating & Re-Inflating Tyres All Sizes
Objective
To provide employees with guidance to follow for safely inflating and re-inflating tyres, and a clear
understanding of the hazards and controls required when performing the tyre inflating task.
Requirement To Use Restraining Device

Employees are required to follow proper inflation practices, and are to ensure that appropriate
restraining devices and remote inflators are being used. Carrying out tyre inflation is one of the
highest risks activities with regards to tyres. A bursting or exploding tyre, wheel or rim assembly
can result in extensive injuries or even death, this applies to all wheel or rim configurations and all
types of tyres.
Special Tools and Equipment

1. A remote inflation device with sufficient hose length to ensure that you remain outside the
trajectory zone.
2. A purpose built and fitted vehicle mounted automatic inflation system, (optional).
3. Safety inflation hose.
4. An appropriate restraining method as described in this procedure.
Critical Rules
 Ensure that the equipment has been either,  Ensure that an exclusion zone has been
locked/tagged out, keys removed or signage established and also some type of warning to
applied indicating not to move the vehicle. other people that inflation is taking place.
 Never inflate a tyre or wheel assembly  Personal must remain outside of the
unless it is restrained by using one of the trajectory zone during the inflation process.
methods described in this procedure.  All tyres that have been operated in a run low
 Always use an extension hose with an inline or run flat condition (less than 80% of the
gauge fitted for checking the pressure, or the cold operating pressure), must be inspected
automatic inflation system supplied on some for damage. If deflation occurs again, then
tyre trucks, or a purpose made tyre safety the tyre must be removed for internal visual
inflation hose. inspection.
 Watch for abnormal conditions from outside  You must be able to control the air flow from
the trajectory zone and discontinue if any are outside the trajectory zone.
detected.  Ensure that tyres, rims and components are
 Wear correct PPE. all correctly matched, and are fitted correctly.
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Dublin 01 4050 135 Page 48
Inspection
A thorough inspection is critical to a safe inflation, watch out for sharp edges, metal burrs and pinch
points, use appropriate gloves when carrying out this inspection of the components.
 Prior to inflation, inspect the assembly to make sure that all the components are correctly
matched next ensure that they are seated correctly. If they are not, then you must seek expert
advice.
 Inspect air lines, connectors and crimps for damage or wear, check the threads on the
inflators for wear, and always replace any damaged or worn out parts.
 Take time to ensure that all wheel components are properly seated.
 Weak airline components can result in an airline failure creating dust and possibly flying
projectiles, this can also cause the hose to whip out of control, potentially causing serious
injury to someone.
 If you are asked to continue an already in progress inflation task, then you must ensure that
you carry out a further full inspection to ensure it is safe to continue.
Preparation
The work area
Although you might be protected in the event of a tyre assembly failing, passers-by might not be,
and could be caught in the trajectory path of a ruptured tyre.
Ensure your work area is safe, prevent other people from entering your work area
and that the area is coned off and signs are erected warning of tyre inflation.
If someone enters the exclusion zone or your work area, then you must stop what
you are doing and investigate as to why they entered a danger area without permission.
Personal Protective Equipment

Always conduct a Risk Assessment, prior to starting the job and ensure that the correct PPE is worn
at all times.
Hazards include
 Noise from compressed air being released in the event of a structural failure.
 Dust and flying debris.
Controls
 Identify the extent of the trajectory zone based on the tyre size and ensure that you are
working outside the trajectory zone until the assembly has been safely inflated. Ensure
inflation warning signs and cones are positioned to ensure that everyone knows what is
happening and to stay out of the area.
 Always wear eye protection as compressed air
can contain or stir up particles (projectiles).
 Compressed air blasts can cause damage to
the skin, never expose unprotected skin to
compressed air.
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Dublin 01 4050 135 Page 49
Suitable Restraining Devices
The following table shows suitable restraining methods that are to be used for different tyre sizes
during inflation for fully deflated tyre.
Commercial truck tyres are not to be inflated from fully deflated whilst on the vehicle.
Mounted back on the Crane/
Type of tyre Tyre changing Tyre cage vehicle with a restraint manipulator arm
machine barrier in place or forklift forks.
Passenger Yes Yes
Light Truck Yes Yes
Commercial
Truck 19.5 to Yes Yes
24.5”
Small OTR or Tyre machine

Agricultral arm can act Yes Yes Yes
smaller than as a restraint
25” for
Wheelbarrow
or ATV tyres
Large OTR or
Agricultral 25” Yes Yes
and larger
1. All restraining devices must be inspected for signs of

damage before use.
2. Tyre cages must NOT be bolted to the floor, and must be at least one
Metre away from any wall or structure.
3. If the manipulator is to be used as a barrier, then it must be grounded
as shown in the picture, with the manipulator fully closed and angled
away from the tyre.
Inflation adjustments conducted on tyre assemblies that are above the 80% rule do not require the
use of a restraining device; however, all other safety aspects must be adhered to.
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Dublin 01 4050 135 Page 50
Restraining The Assembly
The hazard potential of a tyre or tyre assembly failing during inflation can be lethal, positioning
something in front of the assembly to act as a barrier can reduce the potential of debris scatter if the
assembly fails during inflation.
Mounted back on the vehicle with a restaint barrier in place

For OTR & Agricultral tyres, bolt the assmebly to the vehicle, and
utilise a barrier of some design, if using the crane/manipulator, then
it must be grounded, fully closed and at a angle.
Horizontal mount with a restaint barrier in place

For OTR & Agricultral tyres, the crane or manipulator arm is
considered an accepatable restraining device, when placed over the
trajectory zone of the wheel components.
In any restraining situation

 The manipulator equipment must be positioned with the parking brake applied, the wheels chocked
and the operator out of the cab and the trajectory zone.
 Ensure that no-one passes under the arms of the manipulator when used as a barrier. Leave a safe
means of egress so employees can enter/exit the trajectory zone when inspecting/seating the
components.
Selecting An Inflation Device
Select the appropriate device for the type of tyre and wheel assembly being inflated.
 ensure the airline hose is long enough to allow the operator to stay
outside the likely explosion trajectory during inflation
 The shut off for the air flow must be on the remote end of the inflator hose
 Being able to control the air flow and check the pressure remotely, reduces
the need to be in front of the assembly during the inflation process.
 Inspect the inflator components for damage or wear.
 Worn threads or clamps can result in the inflator device coming off of the
valve stem when under pressure and striking and injuring someone.
 Tag and remove damaged components from replacement or service.
 Depending on the size of tyre being inflated, you may be using a clip on style
chuck or a screw type such as an IN-80 or IN-95 inflator. Inflators may have
adaptors for the various sizes of valve stems. Make sure you have the correct
components for the tyre size you are working on.
LC Tyres
22 Ballymount Rd
Dublin 01 4050 135 Page 51
The Trajectory Zone
Tyre and rim assemblies can come apart violently without warning
The trajectory zone is the path that debris etc. will travel in the event of a tyre/rim assembly failing.
Even if it is restrained, there is still a risk of injury or even death if you are in the trajectory zone. So never
stand in the trajectory zone and do not let others stand in the trajectory zone during the inflation process.
The Trajectory Zone

Large OTR and Agriculture
LC Tyres
22 Ballymount Rd
Dublin 01 4050 135 Page 52
Monitoring The Inflation Process
Multi Piece Wheel/Rim Assembly
Stand out of the path of any projectiles and begin to inflate the tyre, whilst carefully
tapping the lock ring, using a soft metal bar and a dead blow hammer at various sections
around the circumference to ensure that the wheel/rim components are seating correctly.
Once the components are seated correctly, then everyone must remain outside the trajectory zone during
inflation.
The maximum pressure for employees inspecting and verifying the correct seating of the wheel/rim
components within the trajectory zone is:
 Passenger/Light Truck/Commercial Tyre – 10 Psi.
 Small OTR/Agriculture – 15 Psi.
 Large OTR/Agriculture – 20 Psi.
Watch for any unusual noise or distortion of movement of the tyre.

 Continuing to inflate a tyre with a defect can result in serious injury or death.
 Listen for abnormal sounds such as popping, snapping or escaping air indicating a possible
structural failure.
 STOP inflation if you need to make a closer inspection or remedy any equipment malfunction such
as a frozen airline or inflation device.
 If you hear or see anything abnormal, STOP and deflate the tyre remotely and determine the
problem.
Problems with sidewall bulges can be minor or they can be indicators of a belt failure, tyres that have been
run flat have the potential for belt breakage resulting in a split failure called a zipper
Arrange your work area so that in the event of a tyre failing you have a safe route of escape, and in the
event of a failure or if it is suspected that a failure is going to occur:
 Do not go toward the tyre assembly to remove the air supply.

 Cut the air supply and deflate remotely if safe to do so.
If everything appears to be okay, continue to inflate to the correct working pressure and once that has
occurred, install the core housing and remove the inflator device, or remove the inflator device and install
the valve core, finally replace the valve cap.
LC Tyres
22 Ballymount Rd
Dublin 01 4050 135 Page 53
Monitoring The Inflation Process
On smaller applications where the core has been removed for inflation purposes, you may have to top up
the air after installing the valve core
 Continue to check the pressure but stay out of the trajectory zone.
 Time spent in front of the assembly must be limited to reinstalling the valve core housing or valve
core, removing the inflator device and installing the valve cap.
 Verify that the valve core and housing are correctly tightened and no leaks are evident.
 Lose valves, caps or core housings can lead to low air pressure and premature tyre failure.
Caution
Liquid and debris can get into the valve stem and become a projectile. Position yourself out of the path of
any projectiles when removing inflators/chucks or when installing/removing valve cores. Wear eye, ear
and hand protection to guard against noise and any liquid, ice or other debris that may spray from the
valve stem when removing the inflator device.
Initial Inflation – Large OTR
When initially inflating a large OTR tyre assembly after mounting, it is critical to ensure that the tyre
beads seat correctly on the wheel/rim components.
In an effort to achieve this, the restrained tyre should be:
 Remotely inflated to 20% above recommend cold inflation pressure.

 Then remotely deflate the assembly back down to the recommend cold pressure if mounted on the
vehicle, or to the cold storage pressure if stored loose.
 Visually inspect to ensure that the distance between the flange edge and the moulded guide rib on
the tyres sidewall is consistent around the circumference.
 Ensure that the rim can withstand the bead seating pressure before commencing seating the bead.
Tire Deflation 80% Rule All Tyres

All tyres that have been operated in a run low or run flat condition (less than 80% of the tyres
normal cold pressure), must be assessed to see if it needs removing for an internal inspection. If the
tyre is not removed and is re-inflated, and subsequently comes back in with low pressure, then it
MUST be removed for a thorough inspection, before being remounted.
The 80% rule is designed to help to identify the root cause of the air loss and to safeguard the safety of the
employee against the hazard of possible tyre or wheel/rim failure during re-inflation. The operating
pressure is defined as “the cold inflation pressure” if at any time an employee is unsure, then he is to seek
advice from their Supervisor/Manager.
There is an additional rule for Large Earthmover tyres above 25”, and that is:
“Where the cause of the air loss cannot be established, then the Low Pressure Flow Chart is to be referred
to, however this has to be authorised by the employees Supervisor/Manager
LC Tyres
22 Ballymount Rd
Dublin 01 4050 135 Page 54
Inflation Process Map
LC Tyres
22 Ballymount Rd
Dublin 01 4050 135 Page 55
Inflation Maintenance
Definition:
Cold pressure is defined as pressure measured from.
 Any tyre taken from stock and fitted, but not in operation.
 Any equipment parked for at least 8 hours without an external heat source.
Hot pressure is defined as pressure measured from:
 Any tyre that is fitted on a machine and that machine is being utilised in production.
Incorrect pressure is defined as:
 Cold pressure below or above the recommend cold pressure setting.

 Hot pressure below recommend cold pressure or 25% above recommend cold pressure setting.
2. Overloading or incorrect loading.
3. Under inflation.
4. Incorrect compressor size.
5. Uncalibrated pressure gauges or master gauge.
6. Poor inflation maintenance.
7. Defective or incorrectly matched rim components.
8. An external heat source.
9. Defective tyre.
Cold Recommend Pressure

0% 75% 100% 125%
Dangerously Underinflated Correctly inflated (slight variance Dangerously

underinflated due to ambient temperatures) overinflated
Important Notes:
1. Tyres that are fitted on rims should be stored at a pressure of 10 Psi.

2. Tyres should only be fully inflated whilst fitted on the machine, or by being restrained by an
approved restraining device, for example:
 Tyre cage.
 Tyre handler.
 Tyre removal machine.
LC Tyres
22 Ballymount Rd
Dublin 01 4050 135 Page 56
Excessive Heat
Definition:
Excessive heat is present if one or more of the following occur:
 A burning rubber smell.

 Smoke.
 An internal tyre temperature above 60̊ C.
 Sticky rubber between the lugs.

2. Welding on the rim with a tyre fitted (can be done, but the tyre must be fully deflated).
3. Contact with power lines, or a lightning strike.
4. Brakes locking on or excessive braking force.
5. Overheating of drive axle components.
6. Internal tyre fire.
Process Map
Important Notes:
Internal temperature should not be checked if there are visible signs of heat present, assume the
internal temperature is above 80̊ C.
LC Tyres
22 Ballymount Rd
Dublin 01 4050 135 Page 57
Electrical Contact
Definition:
Direct or indirect contact with an electrical source, for example overhead power lines or a lightning strike.
1. Working during a thunder storm.
2. Operating within the distance of power lines (this includes arcing).
Process Map
Important Notes:
1. Be aware that electricity can arc.
LC Tyres
22 Ballymount Rd
Dublin 01 4050 135 Page 58
Chemical Degradation
Definition:
External damage caused to the tyre by contact with hydro carbon substance, for example petrol, diesel etc.
1. Leaking final drives.
2. Contaminated equipment, for example a leaking tyre handler or dirty equipment.
3. Wrong lubricants used for fitment.
Process Map
Important Notes:
1. Chemical degradation is not normally repairable.

2. Ensure that the tyres are clean before fitment.
LC Tyres
22 Ballymount Rd
Dublin 01 4050 135 Page 59
Hazardous Pressure
Definition:
Hazardous pressure is when there is a pressure variance of more than 25% of the tyres cold pressure.
2. Overloading or incorrect loading.
3. Under inflation.
4. Defective rim components.
5. An external heat source.
Process Map
Important Notes:
1. Always seek professional advice if you are not sure what the pressure or internal
temperature is.
LC Tyres
22 Ballymount Rd
Dublin 01 4050 135 Page 60
Obvious Irregularities
Definition:
Irregularities are classed as anything that could or has affected the integrity of the tyre, for example:
 Tyre bubbles.
 Cracked wheel components.
 Foreign objects protruding for the tyre.
 Worn lock ring or lock ring groove.
 Visible casing cords.
 Broken or missing wheel studs or nuts.
 Signs of excessive heat.
 Welding with the tyre still fitted and inflated.
Process Map
Important Notes:
1. Tyres should be removed or at least the air removed, the bead broken and the O Ring
removed before any welding can take place on the rim or the rim assembly or any related
components.
LC Tyres
22 Ballymount Rd
Dublin 01 4050 135 Page 61

Earthmoving Tyre Safety - LC Tyres

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Earthmover Tyre Damage

Senior Inspector Agriculture, Mines and Quarries

Section Sub-Section Page Section Sub-Section Page

Swelling or bulging in the flange contact area caused by friction.

Cut by a foreign object in the bead area.

1. Cosmetic repair is advisable before the cords are exposed.

1. Rim inspection is critical before a tyre is refitted to the rim.

There is no process other than to scrap the tyre

1. Bead rupture is irreparable.

Small diameter holes in the rubber on the base of the bead.

Electrical discharge from lightning, or contact with high tension wires.

Base of the bead is deformed.

1. Decreased bead contact increases the risk of uncontrolled tyre deflation.

Damage or deformation to the bead area, due to incorrect handling.

Separation starting from the edge of the chafer, due to fatigue.

1. Bead separation usually results from bead rocking/wear.

Cracks in the centre of the bead.

1. Never mix rim components from different manufacturers.

Damage to the bead area during fitment.

1. Correct bead lubrication is critical to correct and successful fitment.

Diagonal crack around the bead support area.

1. Cosmetic repair is advisable before the cords are exposed

A cut in the shoulder area, but not damaging the casing.

1. Spillage and foreign objects.

1. Shoulder belt separation is irreparable.

1. High speeds, hair pins, sharp cornering or wheel spinning.

Uneven or increasing wear from the shoulder to the tread.

1. High speed cornering, hard braking or rapid acceleration.

1. The reason for uneven wear must be investigated and rectified.

Damage to the shoulder area due to external factors.

1. Machine defects, rock ejector damage or Grader blade.

1. The reason for the damage needs to be investigated and rectified.

1. Shoulder impact is irreparable.

Damage to the shoulder area by the external machine structure.

1. Equipment defects or rock ejector damage.

Cuts which penetrate through the casing in the shoulder area.

1. Poor housekeeping or road conditions.

1. Improper inflation or loading.

1. Cosmetic repair is advisable before the cords are exposed

Cracking or tearing in the sidewall.

1. Undulations or excessive stress.

1. Cosmetic repair is advisable before the cords are exposed.

Damage to the shoulder area by the external machine structure.

1. Equipment defects or rock ejector damage.

Cuts in the sidewall that reach or go through the inner liner.

1. Sharp objects in the work area or spillage.

Pressure loss at the site of a repair.

1. Improper inflation or overloading.

1. Repaired areas are more prone to secondary damage.

A repair that shows signs of a possible failure occurring.

1. Improper inflation or overloading.

1. Repaired areas are more prone to secondary damage.

A cut observed in the sidewall, but not penetrating the casing.

1. Sharp objects in the work area.

1. Bead separation usually results from bead rocking/wear.

1. This only relates to radial tyres.

Destruction of the casing caused by driving with no air in the tyre.

1. Inflation procedures must always be followed.