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Semi-Truck Tire Blowouts: Prevention and Top Causes

January 29th, 2025

John Paul Miller

John Paul Miller

John is a safety specialist with safety and risk management at ATS.

 

You’re driving down the road, living your best life, singing Celine Dion at the top of your lungs, when suddenly you hear a gunshot and see sparks in your mirror.

You freeze. 

There’s no one near you on the road, so unless someone’s randomly shooting off a gun nearby, you’ve blown a tire. 

Womp womp womp.

No truck driver likes tire blowouts. They’re messy and dangerous and can put a serious damper on your freight plans for the day (or week) depending on how bad the blowout is.

As a former truck driver (and now a safety specialist at Anderson Trucking Service), I’ve unfortunately had a few tires blow in my eight years as a truck driver.

Fortunately for you, though, that puts me in a unique position to help you understand what causes a tire blowout, how to prevent it, and how to handle it. I’ll cover each of the following: 

What is a Tire Blowout? 

A tire blowout is a sudden and rapid loss of tire pressure, typically caused by a rupture in the tire casing or tread. This can lead to losing control of the vehicle — especially at high speeds. Also referred to as a burst, this can happen to any tire. 

Causes of Semi-Truck Tire Blowouts 

Tires can blow for a variety of reasons, including: 

  • Underinflation 
  • Overloading
  • Tire defects
  • Road hazards
  • Excessive speed
  • Excess heat
  • Poor tire maintenance 
  • Age and wear

Underinflation 

Underinflation is the most common cause of tire blowouts. Underinflated tires generate excessive heat, which weakens the tire structure. When performing a pre-trip inspection and using a hammer or similar tool to thump your tires, a dense thud is a sure sign of an under-inflated tire. If you think a tire is underinflated, you should always get the gauge on it to determine its true pound-force per square inch (PSI).

Overloading

Exceeding the tire’s weight-carrying capacity puts immense stress on the tire. Most semi-truck tires have a load rating of “H” meaning they can safely carry 6,610 pounds per tire when inflated to 100 PSI. Any more than that and they’re at risk of failing.

This is why it’s important to pay attention to how heavy your loads are and how the weight is being distributed. 

Tire Defects

Manufacturing defects or damage from previous tire impacts or accidents can puncture or damage tires. 

For example, retread (or recap) tires are used tires with a new tread. During the manufacturing process, they replace the old tread with the new one. These tires are cheaper, but they also have a higher failure rate. 

Does that mean these tires are doomed to fail? No, but it does mean they can have a lower tolerance and drivers should regularly inspect them as they would any other tire.

Worn out tire.

Road Hazards

Sharp objects, potholes, or debris can puncture or damage tires and lead to a blowout. 

Excessive Speed

High speeds increase heat buildup and stress in tires, making them more susceptible to blowouts. Most semi-truck tires are only rated for 75 miles-per-hour (mph). 

Now, imagine if you’re driving on underinflated tires at excess speeds. It’s truly a recipe for disaster.

Excess Heat

Rubber is certainly a strong material, but it’s not unfailing. At higher temperatures — around 200 degrees or higher — the tire can start to deteriorate and take the rest of the tire with it. As the tire breaks down, it creates more heat and a blowout can result. 

Excess heat can also cause the tire pressure to increase so much that the tire expands. If the pressure becomes too high, the tire can blow. 

Now, imagine driving in the dead of summer in a state like Florida or Texas. Coupled with a long day, tires that have already seen better days, and excess speeds, you could have a blowout on your hands soon. 

Poor Tire Maintenance

Lack of regular inspections, improper tire rotation, and neglected repairs can contribute to blowouts. 

Age and Wear

Old, worn-out tires are more prone to blowouts. Regularly inspect your tires and monitor tread depth. Don’t delay when it comes to replacing old tires. They’re only designed to last for so long.

Dangers of Semi-Truck Tire Blowouts 

The severity and dangers of semi-truck tire blowouts depend on which tire blows, how it blows, and where. It can result in any of the following: 

  • Loss of control
  • Vehicle damage
  • Injury
  • Death
  • Cargo damage
  • Traffic disruption 

Typically, blowing a drive or trailer tire isn’t as severe as if you were to blow a steer tire (but that isn’t always the case). At the very least, you’ll probably experience some sort of jerk when the tire blows. The blowout could cause the truck to swerve or veer sharply. If it’s bad enough, that loss of control could lead to a rollover or collision. 

As you well know, accidents can result in serious injuries or death to the truck driver and those involved, or everyone can walk away with minor scratches. At the very least, an accident is going to damage your truck, trailer, and cargo being transported. Not only that, but an accident can lead to traffic delays for anyone traversing that particular highway. 

Anyone driving past a semi-truck as they blow a tire is in danger of getting hit by debris or the truck itself. A blown tire will throw debris into the road that can cause further accidents if it hits another vehicle or a vehicle runs it over before the roadway is cleared. 

This is another reason it’s important for vehicles sharing the road with semi-trucks to be mindful around the large machinery — including maintaining a safe following distance, passing quickly and with caution, being aware of blind spots, and avoiding distractions.

Preventing Semi-Truck Tire Blowouts 

A majority of tire blowouts are caused by driver error. That means blowouts can be prevented by following these tips. 

  • Maintain Proper Tire Pressure: Regularly check tire pressure using a reliable gauge and inflate to the manufacturer’s recommended PSI. 
  • Adhere to Weight Limits: Avoid overloading the truck and ensure the cargo is properly distributed. 
  • Inspect Tires Regularly: Check for signs of wear and tear, cuts, bulges, or embedded objects. 
  • Practice Safe Driving Habits: Avoid excessive speeds, sudden braking, and sharp turns. 
  • Perform Regular Maintenance: Follow the manufacturer’s recommended maintenance schedule, including tire rotation and alignment. 
  • Choose Quality Tires: Invest in durable, high-quality tires from reputable brands. 
  • Monitor Tire Temperature: Consider using a tire pressure monitoring system (TPMS) to track tire temperature and pressure in real time.

What to Do if a Blowout Occurs

Now that you know what a blowout is, how it occurs, and how to prevent it, it’s time to figure out what to do if it happens anyway (which isn’t uncommon!). In a nutshell, you’ll want to do the following: 

  • Stay calm
  • Get control of the vehicle
  • Pull into a safe location 
  • Assess the situation
  • Call someone for assistance (whether it’s your company, roadside assistance, or emergency services)

Let’s dive deeper. 

If you hear that unfortunate gunshot sound, remain calm. Panicking can worsen the situation. Grip the steering wheel firmly to maintain control of the vehicle. Avoid sudden braking, as doing so can cause more issues. If you’re not in control of the truck, apply acceleration until you regain control then gently apply the brakes to slow down gradually. 

Once the vehicle is under control, steer to a safe location, such as a shoulder or emergency lane to assess the situation. Before you get out of the truck, put on your hazard lights. Be careful upon exiting. If you can, wait until no one is driving past. To alert other drivers of your situation, place your emergency triangles at 10, 100, and 200 feet. 

Assess your vehicle and tires to determine what tire blew and what damage occurred. You may have only lost a piece of the tire, it could be hanging on the rim, or you could’ve lost the whole tire and been driving on the rim. If part of the tire is still on the rim, you’ll want to remove it. 

No one expects a driver to backtrack to attempt to find the pieces of the tires to clean the roadway. However, if you have debris near you, try to get it off the road. 

Depending on which tire you blew and how much weight is loaded on the remaining tires, you might be able to get your truck a little farther down the road to a truck stop. For instance, if you blow a drive or trailer tire, it usually isn’t as severe. 

If you can drive a few miles down the road to a safe location, take it slow and keep your hazards on. Make sure no part of the tire remains on the rim. Driving on it can generate excess heat and it’ll start sparking. If this happens, you’re in danger of your truck/trailer starting on fire.

If you blow a steer tire, you’ll have to call your company’s emergency or roadside assistance line to have someone fix the tire on the side of the road. They’ll arrange the details to get a nearby roadside technician to you. 

No matter what your next step is, it’s always a good idea to either call your driver manager/dispatcher or send them a message to let them know what’s going on. You could be delayed for a while as you wait for a repair. They can either adjust pickup/dropoff times or get the load repowered. 

Driver in black cap and opened button-down shirt thumping tires on tanker trailer.

Keep Your Tires – and Yourself – Rolling Safely

Tire blowouts are unpredictable, but they don’t have to be inevitable. By understanding the common causes — like underinflation, overloading, road hazards, and heat — and committing to proper tire maintenance, you can significantly reduce your chances of experiencing one.

But even the best-prepared truckers can’t prevent every blowout. That’s why knowing how to handle one safely is just as important as preventing it. Staying calm, maintaining control, and following the right steps can make all the difference in protecting yourself, your truck, and others on the road.

At the end of the day, your safety is the priority. A blown tire might disrupt your schedule, but a well-prepared driver knows how to handle the unexpected. 

Check out these tips for inspecting a tire to familiarize yourself with the parts of a tire and what you should look for. With practice, you’ll know what you're looking for and be able to spot signs of an impending blowout.