Tyre removal, replacement and inflation

Tyre removal, replacement and inflation should only be tackled by competent staff. The main hazards which can arise include:

  • manual handling injuries, which account for nearly a half of all tyre-related incidents reported;
  • tool-related injuries (which make up a quarter of incidents), particularly from handtools such as tyre levers; and
  • compressed-air accidents eg from a ruptured or burst tyre or violent separation of the component parts of the wheel. These accidents tend to result in serious injuries, including fatalities.

Safety during tyre inflation

Inflated tyres contain a large amount of stored energy, which varies according to the inflation pressure and the surface area of the tyre (eg the sidewall of a typical commercial vehicle tyre has to withstand over 34 tonnes of force from compressed air before additional carriage weight is taken into account).

If the tyre fails, an explosive force can be released at an angle of up to 45 degrees from the rupture (which is often, but not always, the face of the sidewall). This has resulted in numerous fatalities over the years. It is crucial that the airline hose between the clip-on chuck and the pressure gauge/control is long enough to allow the operator to stand outside the likely trajectory of any explosion during inflation. This will vary depending on the size of the tyre and its positioning.

Car tyres generally contain less energy than truck tyres and their size and profile make them less likely to fail catastrophically. Sensible precautions are still required, but a restraining device such as a safety cage is not normally necessary.

Light commercial tyres are now commonly found with pressures around 70psi, which may be sufficient to cause serious injury. If so, use enhanced safety measures such as those required for conventional truck/bus tyres. When inflating above 15psi this will include using a restraint such as:

Horizontal stool and clamping
A secured horizontal stool and associated clamping mechanism
Strong, firmly-secured cage
A strong, firmly-secured cage. Consider lining this with mesh to retain debris. For fixed installations it is helpful to mark the safety exclusion zone on the workshop floor as a reminder to staff
Portable restraint
A portable restraint. These are available in the form of a lightweight cover that encloses the tyre and wheel rim and may be particularly advantageous for off-site repairs

Airlines should have quick-release couplings at both ends to allow the tyre to be deflated from outside the likely explosion trajectory if a fault (eg a potential 'zipper' failure of the sidewall) is detected. The valve connector should not require the operator to hold it place.

The pressure gauge/control valve should never be jammed in the open position, nor should 'unrestricted' airlines (ie without a gauge or pressure control device) be used to inflate any tyre. For bead-seating of large commercial tyres, removing the valve core allows faster inflation without using excessive pressure. Split rim wheels are now uncommon but they may be found on older vehicles and in some specialist applications. Unfamiliarity can increase the risk of a catastrophic failure so additional training will probably be required. Use only metal restraints of adequate strength.

The following YouTube video demonstrates the power of a tyre explosion resulting from inflating a damaged tyre.


Special cases

Very large tyres such as those found in agriculture, quarries etc may be too big to fit into a restraint. Safe systems of work will need to be devised to ensure:

  • the wheel is restrained;
  • the effects of any explosion are contained safely; and
  • everyone stays outside the likely explosion trajectory
Explosion trajectory
Illustration showing the likely explosion trajectory of a very large tyre

More information on safety in tyre inflation and deflation, tyre and wheel removal, repair and replacement

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Updated 2023-05-24