Forklift tyres are one of the least-discussed categories of industrial tyre waste, but warehousing, logistics, manufacturing, and distribution operations generate them in consistent and often substantial numbers. A busy distribution centre running a mixed forklift fleet of 30 to 50 trucks replaces tyres on a regular maintenance cycle, and the construction of most counterbalance forklift tyres creates complications that standard tyre recycling guidance does not address.
The core issue is that forklift tyres are not all the same. A counterbalance forklift on a busy loading dock uses a solid rubber press-on tyre that has no air cavity, no bead wire, and fundamentally different processing requirements from a pneumatic tyre. A reach truck uses a different profile again. A rough-terrain telehandler may use a standard agricultural or OTR pneumatic tyre. Each category has its own correct disposal route, and sending solid tyres to a processor expecting pneumatic tyres creates problems in both directions.
This guide clarifies the differences, explains the correct disposal route for each category, and covers the compliance requirements for operations generating forklift tyre waste.
Understanding the construction of the tyre in front of you is the starting point for correct disposal planning. The three main constructions in forklift use are:
Solid press-on tyres are the most common type in counterbalance forklifts used indoors on smooth floors. The tyre is a moulded solid rubber body bonded to a steel band. The steel band presses onto the wheel rim and is retained by the interference fit. There is no air cavity, no bead wire in the conventional sense, and no possibility of a puncture. These tyres are significantly heavier than a pneumatic tyre of equivalent size.
Cushion tyres are a variation on the solid press-on concept, used on small to medium counterbalance trucks operating on flat, smooth indoor surfaces. The profile is shallower than a standard solid tyre and the rubber compound is optimised for smooth floor use. They share the solid construction and steel band mounting of press-on tyres.
Pneumatic tyres on forklifts follow the same air-filled, bead-wire-retained construction as standard vehicle tyres. They are used on rough-terrain forklifts, reach stackers, container handlers, and some outdoor-specification counterbalance trucks. These tyres can be processed through standard tyre recycling routes without the complications that arise with solid tyres.
A solid rubber press-on forklift tyre cannot be processed in a standard tyre baler. The machine is designed for hollow pneumatic tyres that collapse under compression. A solid rubber tyre does not compress in the same way; it resists the baler ram and, if forced, risks machine damage and produces unusable output. Attempting to bale solid tyres alongside pneumatic tyres is a common mistake that creates equipment damage and disposal problems simultaneously.
The steel band bonded to the solid rubber body is another processing constraint. Unlike the bead wire in a pneumatic tyre, which is a loop of steel wire embedded in rubber and separated from the rest of the steel structure, the press-on band is a structural steel component bonded to the full rubber mass. Separating rubber from steel in a press-on tyre requires specialist equipment and a different processing approach from standard tyre recycling.
Solid forklift tyres go to rubber granulation facilities equipped for solid rubber, or to energy recovery at facilities accepting solid rubber sections. The steel band is separated before or during processing and recovered as scrap steel. Not all tyre waste contractors have access to facilities that process solid forklift tyres correctly; confirm the capability of your contractor before arranging disposal.
For most warehouse and logistics operations, energy recovery is the most accessible solid forklift tyre disposal route. The logistics are simpler than specialist granulation because energy recovery facilities accept solid rubber sections without strict particle size or purity requirements. The revenue or disposal cost for solid tyre sections varies by region and facility; confirm current terms with your waste contractor.
Pneumatic tyres on forklifts are processed through the same routes as equivalent commercial vehicle or OTR tyres. The construction is identical: an air-filled rubber tyre with textile or steel cord reinforcement and bead wire retaining the tyre on the rim. Standard tyre recycling equipment handles this category without modification.
For rough-terrain forklift tyres in the OTR size range (typically 400/70-20 to 500/70-24, weighing 60 to 120 kg), the OTR tyre sidewall cutter removes the sidewall before the tread section is baled using the truck tyre baler. This produces PAS 108-compliant bales or energy recovery material, exactly as for equivalent construction plant tyres.
For smaller pneumatic forklift tyres on indoor rough-terrain trucks (typically 6.50-10 to 8.25-15 size range, weighing 15 to 40 kg), the car tyre sidewall cutter handles the smaller sizes, and the MKII tyre baler produces standard bales from the tread sections.
Some pneumatic forklift tyres are foam-filled with polyurethane after mounting to eliminate the puncture risk. This is common on forklifts operating in environments where a tyre deflation during operation would be hazardous, such as loading docks where a collapsed tyre at the dock edge creates a tip-over risk.
Foam-filled tyres look identical to standard pneumatic tyres but are substantially heavier and cut differently. The OTR tyre sidewall cutter can cut many foam-fill constructions, but the polyurethane fill increases cutting force requirements and changes the output section characteristics. Confirm suitability for your specific foam-fill tyre size and fill density with Gradeall International before processing.
Forklift tyre waste is subject to the same UK waste regulations as all other tyre waste categories. The duty of care under the Environmental Protection Act 1990 requires that:
• Waste tyres are stored safely, with fire risk minimised and quantity limits observed.
• All movements of waste tyres are carried out by a registered waste carrier.
• Waste transfer notes are completed for all off-site movements and kept for two years.
• Waste is only transferred to a person who can receive it legally, meaning a licensed disposal facility or authorised registered waste carrier.
For operations generating solid forklift tyre waste, a specific confirmation that your waste contractor can process solid rubber is important before signing a disposal contract. A contractor registered to accept waste tyres may not have access to a facility that processes solid rubber specifically. If the contractor cannot process your solid tyres correctly, the waste may be transferred to an incorrect facility, creating a compliance risk for the waste producer under the duty of care.
For large logistics groups operating multiple distribution centres with substantial forklift fleets, a centralised solid tyre processing arrangement across the group can convert a disposal cost into a manageable and potentially revenue-generating waste stream. The aggregate volume across multiple sites that individually do not justify equipment investment may well justify a centralised solution. Contact Gradeall International to discuss what arrangements make sense for your specific fleet and site configuration.
Understanding the forklift tyre replacement cycle helps with disposal planning. Solid press-on tyres are typically replaced when worn to the wear line moulded into the rubber, usually at 50 to 70% of original rubber depth. In a high-activity warehouse, a drive tyre on a busy counterbalance truck can wear to replacement in 3,000 to 6,000 operating hours.
Pneumatic forklift tyres are assessed for replacement based on tread depth and carcass condition. Unlike most commercial vehicle pneumatic tyres, forklift pneumatic tyres are rarely retreaded because the operating speeds are very low (retreading is primarily advantageous for high-speed applications where the tread wears faster than the carcass). Forklift pneumatic tyres therefore go direct to recycling at end of life without a retread stage.
Solid forklift tyre disposal is more complicated than most operations realise until they try to arrange it and find their usual tyre contractor cannot help. Getting the classification right at the start, understanding whether the tyre is solid press-on, foam-filled pneumatic, or standard pneumatic, determines the entire disposal route. We see unnecessary cost and compliance problems when operations assume all forklift tyres go through the same process.”
No. Solid rubber press-on tyres cannot be processed in standard tyre balers designed for hollow pneumatic tyres. The solid rubber mass does not compress in the way the baler ram expects, creating a risk of machine damage and producing unusable output. Solid forklift tyres require specialist rubber granulation or energy recovery processing.
Solid press-on tyres have no valve stem and are visibly solid rubber with a steel band at the inner diameter. Pneumatic tyres have a valve stem for inflation and a hollow cross-section visible on the inner face. Foam-filled tyres have a valve stem (now sealed) but no hollow cavity when inspected at the inner face.
The steel band from a solid press-on forklift tyre is recovered as scrap steel at the processing facility. The scrap value depends on market conditions and the band weight. For large counterbalance truck tyres with heavier steel bands, this can be a meaningful secondary revenue stream for the processor, though the value accrues to the processing facility rather than the waste producer unless a specific arrangement is made.
Pneumatic forklift tyres in the OTR size range can be processed into bales when the tyre type meets the PAS 108 composition requirements for the bale configuration. Not all OTR tyre sizes are straightforwardly PAS 108 compliant; confirm with Gradeall for guidance on specific forklift pneumatic tyre sizes.
Solid tyres should be inspected at every scheduled forklift service and measured against the wear line. Pneumatic tyres should be checked for tread depth and carcass condition at each service. Both types should be inspected daily as part of the pre-use forklift check required under PUWER and the relevant LOLER requirements for forklift trucks.
Yes. The duty of care under the Environmental Protection Act 1990 applies to all waste, including solid forklift tyres. A waste transfer note must be completed for every off-site movement of solid forklift tyre waste, the carrier must be registered, and the note must be retained for two years. The same requirements apply as for any other category of tyre waste.
Large logistics operations are waste producers subject to the same duty of care as any business. There are no specific sector regulations beyond the general waste framework, but large producers may be subject to enhanced scrutiny from the Environment Agency. Some large retailers and logistics businesses operate voluntary extended producer responsibility schemes. Check with your environmental compliance team and Gradeall International for disposal options appropriate to your scale.
Some forklift tyre suppliers offer managed contracts that include tyre supply, fitting, and end-of-life disposal as a package. These arrangements can simplify administration and compliance documentation. Confirm that the disposal element of such contracts uses registered waste carriers and licensed facilities, and that you receive waste transfer notes as required by your duty of care obligations.
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