Permanently flatproof tyres for mining and industrial equipment
- Zero flats, for the life of the tyre
- Filled on your site or in our workshop
- Cures in 24 to 72 hours
Every flat tyre on a loader, forklift or underground vehicle costs you more than a repair. It costs a machine standing idle, an operator waiting, a service callout and, on a rock face or in a decline, a real safety risk. Frontier Group’s polyurethane tyre fill service removes that risk for good.
We pump a two-part polyurethane compound into your existing pneumatic tyres, where it cures into a solid, resilient core. The tyre keeps its tread, casing and footprint, but it can never go flat again. No pressure checks, no punctures, no unplanned downtime.
Already trusted for engine lubricants and oils, Frontier Group now brings the same reliability to your tyres.
What is polyurethane tyre fill?
Tyre fill (also called foam fill or flatproofing) replaces the air inside a pneumatic tyre with a liquid polyurethane that cures over 24 to 72 hours into a closed-cell elastomer. The result behaves like a tyre inflated to a set pressure, but with nothing inside that can leak.
Fill is supplied in a range of hardness grades matched to your equipment. Softer grades keep ride quality on telehandlers and access platforms; firmer grades stand up to scrap handling, underground loaders and slag-yard machines. Our technicians select the grade for your application and load.
Benefits of flatproof tyres
- Zero flats. Sharp rock, rebar, scrap metal and debris cannot put the machine down.
- Less downtime. No emergency tyre changes, no waiting on a service truck.
- Lower total tyre cost. Filled tyres run out their full tread life instead of being scrapped early from sidewall damage.
- Added ballast. The extra weight improves stability and breakout force on loaders and forklifts.
- Safer sites. Removes the risk of sudden deflation in confined or elevated work areas.
- Works with your existing tyres and rims. No special wheels required.
Equipment we fill
Tyre fill is designed for slow-moving, heavy-duty equipment working on cut-prone ground. Typical applications include:
- Underground mining
- LHDs, scoops, jumbos, shotcrete rigs and utility vehicles
- Surface mining and quarrying
- wheel loaders, graders and support vehicles
- Scrap, demolition and recycling
- material handlers and loaders
- Steel, foundry and slag yards
- yard and handling machines
- Construction
- skid steers, telehandlers, backhoes and compact loaders
- Warehousing and logistics
- forklifts and tow tractors
- Landfill and waste
- compactors and site vehicles
- Access equipment
- scissor lifts and boom lifts
Not sure whether your machines suit fill? Send us your fleet list and we will advise which units benefit and which are better left pneumatic.
Is tyre fill right for every machine?
No, and we will tell you when it is not. Polyurethane does not shed heat the way air does, so fill is not suited to vehicles that travel long distances at speed, including large mine haul trucks. Filled tyres are also heavier and give a firmer ride than pneumatic tyres. For most loaders, forklifts and underground equipment the trade-off is clearly worthwhile; for highway trucks and haul fleets, we recommend pressure monitoring and tyre protection chains instead.
How our tyre fill service works
- Assessment. We review your equipment, tyre sizes, duty cycle and operating conditions.
- Grade selection. We match the fill hardness to the load and target pressure of each machine.
- Filling. Our technicians fill tyres on site or at our workshop using dedicated pumping equipment.
- Curing. Tyres cure for 24 to 72 hours depending on size and grade before returning to service.
- Support. We keep a record of every filled tyre so replacements are matched correctly at end of life.
Fill can be applied to new tyres or to sound used tyres with good remaining tread.
Tyre fill and lubricants from one supplier
Frontier Group already supplies the engine oils, hydraulic fluids and lubricants that keep your fleet running. Adding tyre fill means one account, one delivery schedule and one point of contact for two of the largest consumable costs on any heavy-equipment site.
Frequently asked questions
How long does tyre fill last?
For the life of the tyre. The fill does not degrade, leak or lose pressure. The tyre is replaced when the tread wears out, just as it would be if pneumatic.
Can filled tyres be repaired or the fill removed?
No. Filling is permanent. When the tread is finished, the tyre and fill are disposed of together. Ask us about recycling options for spent filled tyres.
How much heavier is a filled tyre?
Typically two to four times the weight of the same tyre inflated with air. On loaders and forklifts this extra ballast is usually an advantage. We will confirm axle-load limits for your machine before filling.
Does tyre fill affect ride quality?
Filled tyres ride firmer than pneumatic tyres. Choosing the correct softness grade keeps the difference small on most equipment.
How does tyre fill compare with solid tyres?
Solid tyres are purpose-built rubber units that often need specific rims and are limited to smaller sizes. Tyre fill works with your existing pneumatic tyres and rims and covers a much wider size range, including underground mining tyres.
How much does tyre fill cost?
Pricing depends on tyre size and fill grade. As a guide, fill roughly matches the cost of the tyre itself. Most customers recover that cost in avoided downtime within the first year. Request a quote for exact pricing.
Do you fill tyres on site?
Yes. We can fill on site for larger fleets or at our workshop for individual machines and forklifts.
Request a tyre fill quote
Tell us your equipment, tyre sizes and where the machines operate, and we will come back with a fill grade recommendation and a quote.
Or reach us directly:+40 744 438 338office@frontier.ro