One of the most powerful advantages of tire flatproofing—often referred to as “foam filling”—for Off-the-Road (OTR) equipment is its adaptability. Not all jobsites are created equal, and neither are the demands placed on OTR vehicles. From debris-strewn construction zones to steep, uneven terrain, each application presents unique challenges that directly impact tire performance, equipment stability, and operator safety.
That’s where filled pneumatic tires stand apart. Unlike traditional air-filled or solid tires, flatproofed tires can be tailored to the specific needs of an application—helping fleet managers optimize performance, reduce risk, and maintain uptime across diverse operating conditions.
Flatproofing That Adapts to the Job
For more than 50 years, TyrFil™ Flatproofing has helped industries like construction, mining, waste management, agriculture, and rental equipment eliminate flats and keep equipment moving. TyrFil is pumped into a pneumatic tire to replace air with a durable polyurethane elastomer core—removing air as a failure point while preserving flexibility and ride quality.
The result is a flatproofed tire that delivers:
- No flats or blowouts
- A smoother, more controlled ride
- Reduced tire wear and equipment damage
- Greater protection for operators and machines
Preventing tire failures doesn’t just save on tire repair costs—it protects productivity, project timelines, and worker safety.
A Smoother Ride Than Solid Tires
Compared to solid aperture tires, flatproofed pneumatic tires offer significant advantages. TyrFil-filled tires absorb shock and reduce cross-axle vibration and G-force transmission—forces that can contribute to operator fatigue, musculoskeletal strain, and premature wear on equipment components.
This smoother ride is especially important for operators who spend long shifts—often 8 hours or more—behind the wheel on harsh, uneven terrain. Additionally, filled pneumatic tires are more sustainable than solid tires, allowing tire casings to be retreaded and reused for second-life applications.
Beyond Flat Prevention: Additional Benefits of TyrFil
In addition to eliminating flats, TyrFil flatproofing delivers meaningful operational and safety advantages, including:
- Reduced risk of tip-overs caused by sudden air loss
- Improved ballast and stability on slopes or under heavy loads
- Elimination of explosive tire or wheel failures caused by pressure loss
- Fewer bent wheels and damaged rims
- Less mechanical downtime from tire-related issues
- Extended “limp-in” capability, helping equipment safely return without becoming stranded
Why Durometer Matters
One of the most important—and often overlooked—advantages of flatproofing is durometer selection.
Durometer measures the hardness of a material. Higher durometer ratings indicate harder, more rigid materials, while lower ratings indicate softer, more flexible materials. In tire flatproofing, durometer selection directly affects ride quality, deflection, heat management, and load-bearing performance.
Unlike solid tires, polyurethane-filled pneumatic tires allow for customized durometer options that can be matched precisely to the application. This flexibility gives operators greater control over how equipment performs in the field.
TyrFil Durometer Options, Explained
TyrFil offers a range of formulations designed to meet different operational demands:
- Low Durometer (10) – TyrFil™ Flex
Delivers maximum deflection and the most air-like ride, ideal for applications where comfort and shock absorption are priorities. - Medium Durometer (30) – TyrFil™ Pro
A versatile, general-purpose solution suitable for approximately 90% of tire fill applications. - Medium Durometer with Enhanced Heat Dissipation (30) – TyrFil™ Ultra
Designed for severe-duty environments such as underground mining, where heat and load levels are extreme. - High Durometer (55) – TyrFil™ HeviDuty
Provides added durability and minimal deflection for slow-moving equipment carrying high loads.
In addition to material selection, fill pressure can be adjusted to closely replicate pneumatic tire pressure—further fine-tuning performance.
Custom Performance Without Compromise
The ability to select and customize durometer allows OTR operators to get the most out of their equipment—whether it’s a skid steer, wheel loader, excavator, or bulldozer—while ensuring flat-free reliability throughout the life of the project.
With TyrFil flatproofing, equipment doesn’t have to sacrifice comfort for durability or safety for performance. Instead, operators gain a solution that adapts to their environment, protects their people, and keeps operations moving.
To learn more about durometer selection and how flatproofing reduces vibration and operator impact, visit the No More Solid Shock resource hub.