“Behind the Wheel of Safety: Fire Risks and Protection in the Tire Manufacturing Industry”

The Tire Industry: Manufacturing, Fire Hazards & Safety Standards

1. Overview of the Tire Industry

The tire industry is a critical segment of the global automotive and transport sectors. Tires are essential components for vehicles — from two-wheelers and cars to heavy trucks, buses, agricultural machinery, and industrial equipment — providing traction, durability, load-carrying capacity, and safety. The industry has grown rapidly to meet rising demand driven by mobility, logistics, and replacement markets.

In India, the tire manufacturing sector has seen significant development with both domestic and multinational players setting up state-of-the-art facilities for passenger, commercial, and off-the-road (OTR) tires.

However, alongside operational scale comes associated risks, particularly fire hazards, due to the flammable nature of tire materials and storage volumes.

2. How Tires Are Manufactured

Tire manufacturing is a complex, multi-stage industrial process involving raw materials, compounding, assembly, curing, and inspection. Below is a simplified process flow:

2.1 Raw Material Preparation

Tires are made from a blend of:

• Natural and synthetic rubber

• Carbon black and fillers

• Chemicals and additives

• Steel and textile reinforcement cords

These ingredients are weighed, mixed, and compounded to achieve the required performance characteristics.

2.2 Compounding & Mixing

The raw ingredients are processed in mixers to produce various rubber compounds for different parts of the tire (tread, sidewall, beads). Heat and shear in mixers ensure proper dispersion of ingredients.

2.3 Component Preparation

Individual tire components are formed:

• Tread — provides traction and wear resistance

• Sidewalls — protect against impacts and maintain structure

• Belts and plies — steel and textile layers for strength

• Beads — hold the tire on the wheel rim

2.4 Building & Assembly

A specialized tire building machine assembles all components into an uncured tire “green” structure, layer by layer.

2.5 Curing/Vulcanization

The uncured tire is cured in a press under heat and pressure. This vulcanization process chemically bonds rubber molecules, giving the tire its final shape and performance.

2.6 Inspection & Quality Control

Finished tires undergo rigorous inspection and testing before dispatch.

Fire risks exist throughout this workflow — from compounding flammable liquids to mechanical heat generation in mixers and presses. (Risk Logic)

3. Fire Incidents in the Tire Industry

Tire fires are notorious once they start:

3.1 Notable Tire Fire Cases

• Recent tire warehouse fire near Gurgaon, India: A fire broke out in a large tire storage area, producing dense smoke and challenging firefighting efforts. Several fire tenders were deployed to control it. (The Times of India)

• Hagersville Tire Fire (Ontario, Canada): A massive tire fire consumed about 14 million tires and burned for 17 days, requiring significant firefighting efforts and environmental cleanup. (Wikipedia)

3.2 Characteristics of Tire Fires

Tires burn intensely and produce:

• Dense black smoke

• Toxic gases (carbon oxides, hydrocarbons)

• High heat release rates and fire that is difficult to extinguish once established (michelin.in)

4. Fire Hazards in Tire Manufacturing and Storage

Despite not easily igniting, once tyres catch fire they can:

• Burn with sustained heat and dense toxic smoke

• Be difficult to extinguish due to rubber’s heat-retention and insulation properties

• Re-ignite after suppression due to internal heat build-up (michelin.in)

4.1 Common Fire Risks

• Ignitable liquids and flammable chemicals used in compounding stages (Risk Logic)

• Combustible dust from re-tread and cutting operations (Risk Logic)

• Stored finished tires, especially when stacked vertically, can create a “chimney effect” that accelerates fire spread (Risk Logic)

• Spontaneous heating of rubber shreds or stockpiles in recycling or storage areas (HSE)

5. Fire Protection Requirements — Indian & International Standards

Ensuring fire safety requires adherence to codes and standards that prescribe fire detection, suppression, and life safety.

5.1 Indian Standards & Codes

• National Building Code (NBC) – Part IV: Provides comprehensive fire & life safety guidance for building design, passive and active fire protection systems in industrial facilities, and integration of safety engineering principles. (Shubh Fire and Safety Equipments)

• IS 3594: Code of Practice for Fire Safety of Industrial Buildings: Details fire protection requirements for warehouses and storage buildings — including compartmentation, sprinkler requirements, means of egress, and safe storage of materials. (Law Resource)

• Other relevant BIS standards: Include codes for fire extinguishers (IS 2190), alarm systems (IS 2189), water spray systems (IS 15325), and safety signage (IS 12349). (gidm.gujarat.gov.in)

• Local Fire Safety Bylaws and Model Building Bye-laws often enforce NBC provisions in practice. (Ministry of Housing and Urban Affairs)

5.2 International Standards

• International Fire Code (IFC): Includes provisions specific to tire storage and tire rebuilding plants and references sprinkler system standards like NFPA 13. (ICC Digital Codes)

• NFPA 13 — Standard for the Installation of Sprinkler Systems: Addresses design of sprinkler protection for storage and special hazards—including rubber tire storage arrangements and commodity classifications. (Multiscreensite)

• NFPA and fire codes generally provide guidelines for fire detection, fire alarms, safe egress, and fire suppression in industrial settings. (NFPA)

Key fire protection principles include:

• Segregated storage with safe pile heights and separation distances

• Automatic sprinkler systems appropriate for hazardous occupancies

• Fire detection and alarm systems

• Adequate access for emergency responders

• Regular inspection, maintenance, and staff training

6. Fire Protection in Tire Storage & Processing

Proper tire storage minimizes fire risk:

• Maintain clear aisle space and limit pile height

• Store tires on racks or on-side rather than vertical stacks

• Provide access routes and ensure separation between piles and buildings

• Equip warehouses with automatic sprinklers, hydrants, and portable extinguishers (Red River Mutual)

Modern fire safety practice also includes:

• Early fire detection technologies (e.g., advanced detectors and panels)

• Integration of alarm systems with suppression controls

• Emergency response planning and drills

Industrial sites like tire manufacturing plants use scalable fire detection systems combining detectors, manual call points, and integrated alarms to quickly identify and respond to fire events. (boschsecurity.com)

7. Why Fire Hazards Matter in the Tire Industry

Tire fires not only disrupt operations but can:

• Cause major property loss

• Release toxic pollution

• Pose risk to workers and surrounding communities

• Lead to heavy environmental cleanup costs

For example, large tire fires have historically required extensive firefighting resources and long containment efforts due to heat retention and complex fire dynamics. (Wikipedia)

8. Agni Raksha Niti — A One-Stop Fire Safety Solution

Agni Raksha Niti emerges as a holistic solution for tire industry fire risks, offering:

🔹 Fire Risk Assessment & Audit: Identifying hazards in manufacturing and storage workflows.
🔹 Fire Protection Engineering: Designing compliant fire safety systems per Indian and international standards.
🔹 Advanced Detection & Suppression Solutions: Fire alarms, detectors, sprinklers, and integrated emergency systems.
🔹 Emergency Response Planning: Customized strategies and training to protect life and assets.
🔹 Compliance Support: Ensuring adherence with NBC, BIS codes, NFPA and IFC guidelines.

As previously discussed in other materials, Agni Raksha Niti brings end-to-end fire safety planning, implementation, and compliance under one umbrella — minimizing risk while enabling operational continuity and regulatory adherence.

Conclusion

The tire industry’s growth and complexity bring inherent fire risks — in manufacturing, handling of chemical materials, and bulk storage of finished tires. Understanding the manufacturing process, fire behavior of tire materials, and fire protection standards is essential for risk mitigation.

Adhering to Indian codes like the National Building Code and relevant BIS fire safety standards, along with international standards such as the International Fire Code and NFPA 13, provides a strong foundation for fire safety. However, proactive fire protection design, monitoring, and emergency planning are equally critical.

Agni Raksha Niti offers a comprehensive solution tailored to the tire sector’s unique hazards — from risk assessment to system implementation — ensuring safety, compliance, and resilience.