Cutting puncture downtime in truck and bus fleets

Cutting puncture downtime in truck and bus fleets

OKO Truck & Bus seals tread punctures up to 8mm as the vehicle drives. Doses for 22.5-inch tyres, how long it lasts and a step-by-step fleet rollout.

4 min read

The surest way to cut puncture downtime is to stop punctures turning into flats. OKO Original Truck & Bus goes into tubeless tyres before anything happens and seals multiple tread punctures up to 8mm as the vehicle drives, so trucks, buses and trailers stay on the road rather than the hard shoulder. A 22.5-inch tyre takes 2 to 2.8 litres, and in typical long-haul use one fill stays active for roughly 100,000–140,000 km.

Where puncture downtime comes from

A flat on a heavy vehicle rarely costs just a tyre. The vehicle stops, a callout is needed, the load or the passengers wait, and the schedule behind it slips. Slow leaks are a quieter cost: a tyre losing pressure runs hotter and wears faster long before anyone sees a problem.

Puncture repair deals with this after the event. A preventive sealant deals with it as it happens. For a fuller comparison, read preventive tyre sealant vs puncture repair.

What OKO Truck & Bus does in the tyre

  • Seals as you drive: a liquid layer coats the inside of the tread. When a puncture happens, air pressure drives the sealant into the hole, where it forms a strong, flexible, airtight seal.
  • Handles repeat punctures: only a small amount is used for each one, so protection continues through the tyre's service life.
  • No reduced tyre life after a puncture: a sealed tyre should behave in the same way as the others.
  • Longer tyre life: at least 20% under normal operating conditions, by keeping pressure consistent and reducing heat build-up from slow leaks.
  • Retread-friendly: it cleans away with water, allowing frequent and cleaner retreading.
  • Rim-safe: compatible with all standard steel and alloy commercial rims, with anti-corrosion additives.
  • Non-hazardous: non-flammable, non-corrosive, latex-free and non-allergenic.

How much per tyre: 22.5-inch doses

OKO Truck & Bus is commonly used in commercial tyres on wheels up to 22.5 inches. Example doses from the dosage calculator:

Tyre size Dose per tyre Tyres per 25 L drum
385/65 R22.5 2.8 litres 8
385/55 R22.5 2.6 litres 9
13 R22.5 2.6 litres 9
315/80 R22.5 2.5 litres 10
12 R22.5 2.4 litres 10
315/70 R22.5 2.3 litres 10
295/80 R22.5 2.3 litres 10
11 R22.5 2.2 litres 11
275/70 R22.5 2.0 litres 12

Tyres per drum are whole tyres only, rounded down. Confusing 315/80 R22.5 with 13 R22.5? See how to read a tyre size.

Rolling it out across a fleet

  1. Check eligibility. Tubeless pneumatic tyres only: inner tubes in heavy commercial vehicles are too weak under road loads to seal reliably. Confirm the TPMS type. Most direct systems with valve-mounted sensors and narrow air passages are not compatible; wheel- or rim-mounted sensors outside the valve assembly generally are.
  2. Start with new or fresh tyres. That gives the longest protection, so fitting at tyre change is the natural point to begin.
  3. Standardise doses. Take each size from the calculator and write it on a workshop card. The Metallic Application Pump for 25L Drums has an adjustable collar set at 50, 100, 150 or 200 ml and delivers up to 250 ml per stroke.
  4. Apply through the valve. Put the valve at 4 or 8 o'clock, remove the core with a valve core remover and inject. The pump works against up to 60 psi (4.1 bar); if the tyre is at a higher pressure, deflate to that level first, then reinflate with a tyre inflator.
  5. Finish each wheel. Close the tap, let air blow out of the valve for a few seconds to clear residue, refit the core, inflate to the manufacturer's recommended pressure and drive a short distance so the sealant spreads.
  6. Look after the pump. Unscrew it, replace the drum cap and flush the pump with clean water so sealant does not dry inside.
  7. Plan the top-up. In long-haul use the sealant stays active for approximately 100,000–140,000 km (60,000–90,000 miles), depending on climate and operating conditions. If the tyre still has legal tread at that point, top it up.

The bottle method and more detail are in how to put sealant in a tyre.

Know the limits

OKO Truck & Bus seals the tread area, up to 8mm. Sidewall damage cannot be sealed by any tyre sealant. It is designed for vehicles over approximately 5 tonnes; vans and light commercials under that weight use OKO Original 4x4 & Van. For winter routes, its freezing point is -25 °C to -30 °C.

Quick answers

How long does truck tyre sealant last?

In typical long-haul use, OKO Truck & Bus stays active for approximately 100,000–140,000 km (60,000–90,000 miles), depending on climate and conditions. If legal tread remains, it can be topped up.

Can I use sealant in truck inner tubes?

No. OKO Truck & Bus is for tubeless tyres only. Inner tubes in heavy commercial vehicles are too weak under road loads to seal reliably.

Is it compatible with TPMS?

It is not compatible with most direct TPMS that use valve-mounted sensors with narrow air passages. It is generally compatible with wheel- or rim-mounted sensors outside the valve assembly. Confirm your system type first.

How much sealant does a 315/80 R22.5 tyre need?

2.5 litres, according to the OKO dosage calculator. One 25 litre drum covers ten tyres of that size.

Work out your fleet's doses in the dosage calculator and order OKO Original Truck & Bus in 25 litre drums. Our online shop delivers in the UK only; outside the UK, find a distributor.