OTR Tyre Disposal: Safe Methods for Oversized Industrial Tyres

Updated on: 22nd February 2026 By:

Kieran Donnelly
Expert review by:

Off-the-road (OTR) tyres are built to withstand conditions that would destroy ordinary tyres within hours. The same properties that make them exceptional in service, enormous size, thick multi-ply construction, and heavy steel reinforcement, make them one of the most difficult waste materials to handle, transport, and process at end of life.

A large mining haul truck tyre can weigh over 5,000kg and stand more than 4 metres tall. Even a modest loader tyre weighs 300 to 500kg and has a diameter that makes manual handling impossible. These dimensions and weights create challenges at every stage: removing the tyre from the vehicle, moving it on site, transporting it off site, and processing it at a recycling facility.

Stockpiling unprocessed OTR tyres is not a viable long-term solution. They take up enormous space, create significant fire risk, and attract regulatory attention. Landfill disposal of whole tyres is banned in the UK and across the EU. The only compliant and practical route is processing to reduce size and prepare the material for downstream use.

The Main Methods for OTR Tyre Disposal

On-Site Size Reduction

For many OTR tyre operations, particularly at remote mine sites or large quarries, transporting whole OTR tyres to a central processing facility is impractical or uneconomical. The logistics cost of moving a 5,000kg tyre that takes up a full trailer by itself makes off-site processing unattractive until the tyre has been reduced in size.

On-site size reduction using dedicated OTR cutting equipment transforms the tyre from an unmanageable whole into sections that fit standard transport, dramatically reducing logistics cost and making off-site processing viable.

Gradeall manufactures a range of OTR tyre processing equipment designed for this purpose. The OTR tyre splitter cuts large OTR tyres into two halves, reducing the largest dimension immediately and making the halves manageable for further processing or transport. The OTR tyre sidewall cutter removes the sidewalls, further reducing size and preparing the tyre body for baling or shredding. The OTR tyre cutting equipment range covers the full spectrum of OTR processing needs.

Baling After Pre-Processing

OTR tyres cannot be baled whole. The sheer size and rigid structure of an unprocessed OTR tyre exceeds the capacity of any conventional tyre baler. However, after splitting and sidewall removal, the reduced sections can be baled using an appropriately specified baler.

The MKII Tyre Baler handles pre-processed OTR tyre sections effectively. The combination of splitting and sidewall cutting produces sections that compress well, and the resulting bales can be transported in standard containers and supplied for energy recovery or further processing.

Shredding

Industrial tyre shredders can process OTR tyres into chips, though most entry-level shredders are not rated for the very largest OTR tyres without pre-processing. Pre-splitting with an OTR splitter before shredding reduces the load on the shredder’s cutting system, extends blade life, and increases throughput rates.

Energy Recovery

OTR rubber, like all tyre rubber, has a high calorific value that makes it a valuable fuel for energy recovery processes. Cement kilns and large industrial energy recovery facilities accept tyre-derived fuel (TDF) in various forms, including whole OTR sections, chips, and crumb. The pre-processing requirement depends on the specific facility and its feed specifications.

Safe Handling of OTR Tyres: The Physical Risks

The handling risks associated with OTR tyres are distinct from those of car or truck tyres. The weight alone makes manual handling impossible; OTR tyres must be moved with appropriate mechanical equipment at every stage.

Equipment requirements for OTR tyre handling:

On a mine or quarry site, large OTR tyres are typically moved with wheel loaders, cranes, or specialised tyre handlers. The equipment specification must match the tyre weight; attempting to move a 4,000kg tyre with equipment rated for less creates obvious risks.

When processing OTR tyres with cutting equipment, the tyre must be stable before cutting begins. An unsupported OTR tyre will roll under its own weight and become unpredictable during cutting. Proper positioning jigs and support frames are part of the equipment setup for OTR processing.

Inflation risks:

OTR tyres removed from service sometimes retain residual pressure, even if the tyre appears deflated. A tyre that is punctured but not fully deflated can still hold dangerous pressure, particularly at the bead seat area where the tyre contacts the rim. Any OTR tyre being processed should be confirmed as fully deflated before cutting operations begin.

Fire risk:

Stockpiles of OTR tyres are a significant fire risk. The large rubber mass burns intensely and is extremely difficult to extinguish once ignited. Storage should comply with fire risk management requirements, with adequate separation distances and access for fire-fighting equipment.

Processing Equipment for OTR Tyres

The Gradeall OTR processing range addresses the full size spectrum from large van and light commercial OTR tyres through to the largest mining and civil engineering tyres.

Equipment	Application	Key Capability
OTR Tyre Sidewall Cutter	Sidewall removal from OTR tyres	Removes sidewall before baling or shredding
OTR Tyre Splitter	Splits large OTR tyres into two halves	Reduces largest dimension for transport and processing
OTR Tyre Cutting Equipment Range	Complete OTR size reduction	Full range of cut configurations
Agricultural Tyre Shear	Cutting agricultural and tractor tyres	Handles agricultural OTR tyre geometries
MKII Tyre Baler	Baling pre-processed OTR sections	Produces dense bales from cut sections

For sites dealing with a mixed OTR tyre stream, the combination of a splitter and sidewall cutter before baling creates a manageable processing workflow. The splitter handles the initial size reduction; the sidewall cutter prepares the sections for baling; the baler produces the final output for transport and downstream use.

Regulatory Context for OTR Tyre Disposal

OTR tyres are subject to the same waste tyre regulations as other tyre types in the UK. The Waste (England and Wales) Regulations 2011 implement the EU Waste Framework Directive in England and Wales, and similar legislation applies in Scotland and Northern Ireland. The key requirements are:

Whole tyres cannot be landfilled (this has applied since 2003)
Tyre storage must comply with environmental permit conditions
Tyre movements must be tracked by registered waste carriers
End-of-waste criteria apply if tyres are to be treated as a product rather than waste

For mine and quarry sites, the volume of OTR tyres generated annually is substantial enough to warrant a formal tyre waste management plan as part of the site’s environmental management system. This plan should address how tyres are removed from vehicles, stored on site, processed or prepared for transport, and moved off site by registered carriers.

Frequently Asked Questions

Can OTR tyres be processed on site at a mine or quarry?

Yes. On-site processing using an OTR splitter and sidewall cutter is practical and cost-effective for sites generating significant OTR tyre volumes. Processing on site reduces the tyre to a transportable form before it leaves the site, cutting logistics costs substantially. See the OTR tyre cutting equipment range for equipment specifications.

What is the largest OTR tyre that Gradeall equipment can process?

The OTR range is designed to handle tyres up to and including the largest sizes used in surface mining and civil engineering. Contact Gradeall International with your specific tyre dimensions and we can confirm which equipment configuration is appropriate.

Are OTR tyre bales eligible for PAS 108 civil engineering applications?

PAS 108 specifically covers tyre bales for civil engineering. The standard’s requirements for bale dimensions, mass, and density are designed around car and truck tyre bales. For OTR tyre sections, the relevant application is typically energy recovery or further shredding rather than direct civil engineering use. Confirm the applicable specification with the intended end user before committing to a processing approach.

How should OTR tyres be stored before processing?

In a designated storage area, away from ignition sources, with adequate separation distances per fire risk management requirements. Tyres should be stored in a way that prevents water accumulation (which creates mosquito breeding habitats and may trigger additional regulatory requirements). Record quantities and movements to support permit compliance.