CURED TYRE DEFECT

DIRECTORY

By S K JAGASIA
skjagasia@rediffmaill.com

Cured Tyre Defect Directory SKJ Page 1

 PREFACE

I BEAD DEFECTS
1 CRACK AT RCL
2 PINCHED BEAD
3 PULLED BEAD
4 NARROW BEAD
5 BENT BEAD/KINCKED BEAD
6 LIGHT BEAD
7 RCL BLISTER
8 BUCKLED BEAD
9 DEFECTIVE BEAD
10 CHAFER CRACK
11 OFF CENTRE LOADING
12 WIDE BEAD
II SIDEWALL DEFECTS
1 LIGHT SIDEWALL
2 CRACK/BLISTER ON BUTRESS
3 SIDEWALL CRACK
4 SIDEWALL BLISTER
5 RCL FLASH
6 CORD ON SIDEWALL
7 MIS PLACED SERIAL
8 OPEN SIDEWALL SPLICE
9 SIDEWALL SEPARATION
III TREAD DEFECTS

1 HEAVY RIND
2 TREAD SEPERATION
3 TREAD LAMINATION
4 HEAVY UNDER TREAD
5 OPEN TREAD SPLICE
6 SPONGY TREAD

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 IV CARCASS DEFECTS
1 BUCKLED CARCASS
2 PLY SEPARATION
3 SPREAD CORDS
4 LEAKY BLADDER
5 LOOSE CORDS
6 MISSING CORD
7 CARCASS CRACK
V OTHER DEFECTS
1 SPONGY
2 TEMPERATURE FAILURE
3 LOW HP/HW
4 O- RING LEAK
5 TRIMMING DAMAGE
6 DE-SHAPED TYRES
7 UNDER CURE
8 OVER CURE
9 FM CONTAMINATION
10 INNER PAINT CONTAMINATION
11 OFF MOULD REGISTER/ALLIGNMENT
12 NO PCI
VI ABBREVIATIONS
1 RCL RING CENTER LINE
2 LSW LIGHT SIDEWALL
3 OTS OPEN TREAD SPLICE
4 HP HIGH PRESSURE
5 HW HOT WATER
6 FM FOREIGN MATERIAL
7 PCI POST CURE INFLATION

Cured Tyre Defect Directory SKJ Page 3

 1. CRACK AT RCL

POSSIBLE CAUSES ACTION

Check the ply widths
Ply width off Set the ply widths as per spec at bias cuter
Excess width plies to be cut to specified width at building
Ply angle high Check the ply angle and consult Techf If it is high
Wrong bead filler Ensure correct usage of bead filler
Tread ends thick Make the tread edges thin in consultation with Tech
FM in tread ends Clean the foreign maters embedded in tread ending
Drum set high Check the drum set and set it right
Wrinkled turn ups Caution the tyre builder
Check the working and travelling of back / bottom sttcher
Wrinkled treads at edges Check the tread width, higher width tread will lead to
wrinkling ot treads hence do not use
Of cantered tread Check tread centering pointer and set it right
Curing ring block vents Get them cleaned by pin venting
Dirty curing rings Get it cleaned
Avoid deformaton, store them on rack and do not keep
Deformed green tyre
the green tyre one over the other
Old green tyre Green tyres are to be used on FIFO basis and consult Tech

Cured Tyre Defect Directory SKJ Page 4

 2. PINCHED BEAD

POSSIBLE CAUSES ACTION

Ply angle high Check ply angle, if angle is high do not use the fabric
Ply gauge high Check ply gauges and do not use the fabric with high gauge
Bead perimeter low Check the beads on BPR if tight reject them
Wrong bead core Check the beads for number of strands and layers
Drum set high Check the drum set and set it right
Turn down ply more Check the ply width and correct it at bias cuter or building
Loose turn ups Caution the tyre builder
Wrinkled turn downs Caution the tyre builder
Wrong chafer Check the correct usage of chafer
Check whether part nof 1 & 5 are correct, if ledge width is less
Wrong curing ring
pinched bead defect can come
Wrong moulding Ensure correct tyre size
Of centre loading Avoid deformaton, take full care while loading
Bladder lock nut height more,
which touches to platen in press Replace the bladder clamps with lesser height clamp
close condition
Avoid deformaton of green tyre, store the green tyres on racks,
Deformed green tyre
do not keep the tyre one above the other
Higher weight tyre will lead to pinched bead defect, as excess
Green tyre weight more
material at bead will come as pinch
Piston cylinder bend Check the piston cylinder and replace

Cured Tyre Defect Directory SKJ Page 5

 3. PULLED BEAD

POSSIBLE CAUSES ACTION

Ply angle low Check ply angle if low do not use the fabric& advice fr Tech
Bead perimeter high Check the beads on BPR, if loose reject them
Wrong bead core Check the number of strands and layers
Drum set low Check the drum set and set it rightf
Turn down ply less Check the ply widths and set it right at bias cutter
Off cantered bead Check the concentricity of BPR with drum and set it right
Off cantered ply Check ply centering guide and set it right
Wrong chafer Ensure correct usage of chafer
Shaping excess Adeust shaping pressure as per spec
Wrong moulding Check the green tyres for proper size and identification
Off centre loading Care is to be taken while loading for proper centeringf
Avoid deformaton, keep the green tyres on racksf Do not keep
Deformed green tyre
the tyre one over the other

4. NARROW BEAD

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 POSSIBLE
CAUSES ACTION
Ply width less Check ply width, if less then do not use
Ply angle low Check ply angle, if low then do not use
Bead perimeter high Check the beads on BPR, if beads are loose, reject them
Wrong bead core Check number of strands and layers in a bead
Off cantered bead Check concentricity of BPR and drum, and correct it
Off cantered ply Check ply centering guide and set it right
Wrong chafer Ensure about correct usage of chafer
Wrong curing ring Ensure specified curing ring usage
Set the shaping pressure as per specf, if shaping found
Shaping improper
improper get it rectified
Shaping excess Set the shaping pressure as per specf or reduce if required
Avoid wrong moulding, check for correct size and
Wrong moulding
identification
Off centre loading Care is to be taken while green tyre loading
Avoid deformaton, store them on rack and do not keep
Deformed green tyre the green tyre one over the other; keep minimum green
tyre inventory

5. BENT BEAD/KINKED BEAD

POSSIBLE CAUSES ACTION

Ply angle low Check ply angle, if low then do not use
Bead perimeter low Check the beads on BPR if tight reject them
Wrong bead core Check number of strands and plies in a bead
Drum set low Check the drum set and set it right
Vacuum high Check the vacuum and set it as per spec
Tyre stuck up to the mould Check mould lubricant application or bead oil
Cured Tyre Defect Directory SKJ Page 7
 application
Wrong bladder usage Ensure correct usage of bladder
Check cold water supply tempf and if high check cooling
Cold water tempt not as per spec
tower fan operation and inform Utility
Check cold water circulation pressure and set it as per
Cold water circulation improper Spec (In circulation Pressure should be same as HW
Check cold water returns operation proper flow
Avoid deformaton, store them on rack and do not keep
Deformed green tyre the green tyre one over the other; keep minimum green
tyre inventory
Over life bladder usage Check the bladder conditon and replace
Check cold water circulaton, drain, and vacuum
operations
Bladder bulging
Check for any blockages in inlet / outlet pipelines & get
it corrected

6. LIGHT BEAD

POSSIBLE CAUSES ACTION

Bead perimeter high Check the beads on BPR, if beads are loose, reject them
Wrong bead core Check number of strands and layers in bead core
Check the gauge and fabric
Chafer setting and gauge Check for cleanliness of curing ring and blockages of vent holes
Get them pin vented
Check ply width ,correct it at bias cuter and do not use
Turn down ply less
lower width fabric
Loose turn ups Caution the tyre builder
Wrong chafer Ensure correct usage of chafer

Curing ring block vents Get them cleaned by pin venting

Dirty curing rings Get them cleaned

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 Wrong curing ring Ensure correct usage of curing ring
Avoid deformaton, store them on rack and do not keep
Deformed green tyre the green tyre one over the other; keep minimum green
tyre inventory

7. RCL BLISTER

POSSIBLE CAUSES ACTION

Tread width low Check tread width and if low reject them
Tread ends thick Reduce the thickness at tread edges
FM in tread ends Clean the foreign mater embedded in tread ends
Improper tread Skive Correct the tread skive at extruder and consult Tech
Get them poked though awl
Ensure the knurling roll usage at extruder
Air traps under cushion

Check the cushion gauge at extruder, thinner cushion

gauge will lead to air traps
See the applicaton and working of bottom sttchers
Wrinkled treads Freshen the plies with approved solvent / naphtha
Ensure C118 / tread cement application on tread base
Of cantered tread Check tread centering pointer and correct it
Wrong chafer Ensure correct usage of chafer
Curing ring block vents Get them cleaned by pin venting
Foreign maters Get them cleaned
Avoid deformaton, store them on rack and do not keep
Deformed green tyre the green tyre one over the other; keep minimum green
tyre inventory
Old green tyre Green tyres are to be used on FIFO basis and consult Tech
Air traps in ply / tread while Check for working of bottom sttcher
Cured Tyre Defect Directory SKJ Page 9
 Freshen the plies with solvents / naphtha
building
Apply hand sttcher before bottom sticher application
Chafer usage Ensure right chafer usage

8. BUCKLED BEAD

POSSIBLE CAUSES ACTION

Apply inner lube on under cut of green tyre at bead
Improper inner lube region
applicaton
Get the green tyres re sprayed
Check the vacuum and set it as per specf if required
Vacuum high
throtle the vacuum gate valve
Check the shaping, set as per specf if required get it
Shaping improper
rectified
Wrong moulding Check for correct size green tyre and its identification
Of centre loading Take care while loading
Over life bladder Check the bladder conditon and get it replaced
Wrong bladder Ensure the correct bladder usage as per spec
Check the leakage through the valve drain, vacuum, cold
Low HP steam
water return, hot water recovery and get it rectified
Check the functoning of HP supply valve , chocking and
non-return Valve
Delayed HP steam

Avoid deformaton, store them on rack and do not keep

Deformed green tyre the green tyre one over the other; keep minimum green
tyre inventory

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 9. DEFECTIVE BEAD

POSSIBLE CAUSES ACTION

Wrong bead core Check number of strands and layers in bead core
Of centre curing ring Check the centering of curing ring wfrftf mould and get it
corrected
Damaged curing ring Check for any damages on curing ring and replace
Wrong curing ring Check for correct usage of curing ring

10. CHAFER CRACK

POSSIBLE CAUSES ACTION

Tread length low Reject them
Tread width low Reject them
Reduce the gauges at tread ending in consultaton with
Tread ends thick
Tech
FM in tread ends Clean the foreign mater embedded in tread ending
Chafer set low Ensure correct chafer setting
Loose turn ups Caution the tyre builder
Off cantered tread Check the tread centering pointer and set it right
Check tread width, if more reject the treads
Excess tread stitchout Check the back sttcher pressure
Check the botom sttcher pressure, if high, set it as per spec

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 11. OFF CENTER LOADING

POSSIBLE CAUSES ACTION

Bead perimeter low Check the beads on BPR, if beads are tght, reject them
Wrong bead core Check the beads for number of strands and plies
Off cantered bead Check concentricity of BPR and drum, and correct it
Off cantered curing ring Check centering of curing ring with respect to mould
Wrong curing ring Ensure correct usage of curing ring
Check the shaping, set as per specf if required get it
Shaping improper rectified
Wrong moulding Avoid wrong moulding, check for correct size and identfcaton
Of center loading of green tyre
Train the press operator
by the operator
Check top ring down operaton;
Bladder collapsing while shaping
Check for any hydraulic leaks; get them rectified
Check shaping pressure and set it right

Shaping getng cut while Set the shaping ‘cams‘

loading Check pause height and time
Check any leakage through any valves
Bladder height more Set it as per spec
Avoid deformaton, store them on rack and do not keep the
Deformed green tyre green tyre one over the other keep minimum green tyre
inventory
Old green tyref Green tyres are to be used on FIFO basis or consult Tech
Piston cylinder bend Check the piston cylinder and replace

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12. WIDE BEAD

POSSIBLE CAUSES ACTION

Wrong bead core Check number of strands and layers in bead core
Tread gauge high Check the tread gauges, if high consult Tech
Drum set high Check the drum set and set it right
Loose turn ups Explain / Caution the tyre builder
Loose turn down Explain / Caution the tyre builder
Check whether building constructon is followed as per specf or
Wrong ply
not
Wrong curing ring Ensure usage of correct curing ring
Ply gauge high Check ply gauge, if high consult Tech

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 Sidewall Defect

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 1. LIGHT SIDE WALL

POSSIBLE CAUSES ACTION

Wrong tread stock Use tread stock as per specf Which is released as OK by Techf
Tread length low Reject the treads
Low side wall gauges Reject the tread
Wrinkled turn ups Explain / Caution the tyre builder
See the applicaton and working of back / bottom stitches
Freshen the plies with approved solvent / naphtha
Wrinkled treads
Ensure C118/ tread cement application on tread base
Check the back / bottom sttcher pressure
Of cantered tread Check tread centering pointer and correct it
Blocked mould vents Clean them by pin venting
Less mould vents Increase the mould vents in consultation with Tech
Dirty SW (mould) Clean the mould / send the mould for sand blasting
Check the shaping, set as per specf if required get it rectfed
Shaping improper
from Engg Dept
Mould lubricant excess Check the applicaton and concentrating of mould lubricant
Mould temperature Set the mould tempt as per spec
Top 'O' ring leak Replace the leaky ‘O’ ring
Steam leak in mould Arrest the steam leaks
Check the source from where water is coming on the mould and
Moisture (water) in mould arrest the leaks
Blow out the water from mould
Blocked botom mould surface Clean all the air channels from the botom surface of the
moulds
lines
Foreign maters Clean the foreign mater which is on the mould
Avoid deformaton, store them on rack and do not keep the
Deformed green tyre
green tyre one over the other
Old green tyre Green tyres are to be used on FIFO basis and consult Tech
Platen leaks Arrest the leaks/ check hose pipe as well

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 Clean fitter of dome drain
Water below ring part no 1 Check NRV of dome steam line
Check steam trap functioning
Water on ring part no 3 Check top ‘O’ ring leakage
Check suction pipe

2. CRACK/BLISTER ON BUTTRESS

POSSIBLE CAUSES ACTION

Tread length off Reject the material
Tread gauge low Increase the gauges

Of cantered tread Check tread centering pointer and set it right

Foreign maters Clean the foreign mater
Avoid deformaton, store them on rack and do not keep
Deformed green tyre the green tyre one over the other ;keep minimum green
tyre inventory
Old green tyre Green tyres are to be used on FIFO basis and consult Tech
Of side wall applicton (truck) Check side wall applicaton and caution the tyre builder
Contaminated treads Check for any contaminaton of FM in tread or side wall

3. SIDEWALL CRACK

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 POSSIBLE CAUSES ACTION
Wrong bead filler Ensure correct filler usage
Wrong bead flipper Ensure correct flipper usage
Tread gauge high Reduce tread gauges
FM in tread ends Clean the tread endings
Wrinkled turn ups Caution tyre builders
See the applicaton and working of bottom stitcher
Wrinkled treads Freshen the plies with naphtha/ solvents
Ensure C118 / tread cement application on tread base
Check tread width, if excess reject the treads
Excess tread sttchout
Check the botom sttcher pressure, if high, set it as per spec
Bottom sttcher pressure high Set it as per specf, excess pressure lead to more tread stitch out
Blocked mould vents Clean them by pin venting
Less mould vents Increase mould vents If necessary
Check the shaping, set as per specf if required get it rectfed
Shaping improper
from Enggf Dept
Wrong moulding Avoid wrong moulding, check for correct size and identfcaton
Off centre loading Train the press operator
Mould lubricant excess Check the applicaton and concentrating of mould lubricant
Check the functoning of HP supply valve and non-return valve
Delayed HP steam
and rectify
Check the source from where water is coming on the mould and
Moisture (water) in mould arrest the leaks
Blow out the water from mould
Foreign mater Clean the foreign mater
Avoid deformaton, store them on rack and do not keep the
Deformed green tyre green tyre one over the other ; keep minimum green tyre
inventory
Old green tyre Green tyres are to be used on FIFO basis and consult Tech
Improper green tyre cleaning Reeect the green tyres / get them cleaned

4. SIDEWALL BLISTER

Cured Tyre Defect Directory SKJ Page 17

 POSSIBLE CAUSES ACTION
Use tread stock as per specf (Which is released as OK by
Wrong tread stock
Tech)
Tread length more Reject them
Low side wall gauge Increase the gauges
Fabric moisture high Check moisture percentage and consult Tech
Remove bare fabric and if already used, apply C118
Bare fabric
solution
Check for working of back / bottom sttcher
Check for back / bottom sttcher pressure
Freshen the plies
Ply /tread air entrapment Pat the treads by hand on side wall
Apply hand sttcher before bottom sttcher application
Check the side wall gauges, if side wall gauges are thin get
the increased
Check for poking needle length
Check for number of holes and position
No poking of green tyres
Check for thr’ & thr’ poking
Poke the air traps
Bottom sttcher pressure high Set it as per spec
Foreign maters on sidewall Clean the foreign matters
Avoid deformaton, store them on rack and do not keep
Deformed green tyre
the green tyre one over the other
Old green tyre Green tyres are to be used on FIFO basis and consult Tech

5. RCL FLASH

POSSIBLE CAUSES ACTION

Wrong curing ring Ensure the correct usage of curing ring
Gap between mould and part Reeect / replace the part no 1
no 1 Piston cylinder is not going down fully afer lower ring

Cured Tyre Defect Directory SKJ 18

 down
Check for any foreign mater between mould surface
and part no 1
Check for bend part no 1 and replaced
Eccentric fitment of part no 1; get it rectified
Check for mould and curing ring part nof 1
dimensions at the register area

6. CORD ON SIDEWALL

POSSIBLE CAUSES ACTION

Poor squeegee on calendered Do not use the fabric
fabric Inform 4-Roll calendar
Use hot knife while cutng the plies/ or while flling of plies in
Hot knife not usage while ply the servicer
cutting Remove the loose cord while building
Cut the loose cord from the green tyre
Improper green tyre cleaning Clean the green tyre and ensure that cord is not on the tyre
Avoid rolling of green tyre on floor
Bad handling of green tyres on
Stack the green tyre on the racks
shop floor
Do not throw the green tyres on floor near building machine

7. MIS PLACED SERIAL

Cured Tyre Defect Directory SKJ Page 19

 POSSIBLE CAUSES ACTION
Check the serial punched holes, they should be thr’ & thr’
Improper holes on serials Take up with supplier
Re punch the holesf
Damaged hole thread on
Re thread the mould
mould
Improper mould blowing Check mould air blowing pressure
Caution the press operator
Remove the serial in mould cavity and cylinder pits

8. OPEN SIDEWALL SPLICE

POSSIBLE CAUSES ACTION

Tread length low Reject the tread
Improper tread skive Correct the tread skive at extruder and consult Tech
Improper tread splicing Check tread splicing, it should be of set by 2 mmf, cauton
the tyre builders
Freshen the tread splice with naphtha
Ensure C118 / tread cement solution on tread splice
Side wall ends to be stretched and pressed one over the
otherfThey should not be open
No tread splice pressing / Check whether tread splice is cemented or not
eamming Check tread splice eamming pressure and set it right
Shaping excess Check the shaping, set as per specf if required get it
rectified
Foreign maters Clean the foreign mater
Deformed green tyre Avoid deformaton, store them on rack and do not keep
the green tyre one over the other
Old green tyre Green tyres are to be used on FIFO basis and consult Tech

Cured Tyre Defect Directory SKJ Page 20

 9. SIDEWALL SEPERATION

POSSIBLE CAUSES ACTION

Use tread stock as per specf (Which is released as OK by
Tread stock
Tech)
Tread length high Reject them
Tread gauge low on side wall Increase the gauges
Fabric moisture high Check moisture percentage
Remove bare fabric , and if used already apply C118
Bare fabric usage
Or approved solution
Check for working of back / bottom stitcher
Check for back / bottom sttcher pressure
Ply /tread air entrapment Freshen the pliesf
Pat the treads by hand on side wall
Apply hand sttcher before bottom sttcher application
Check for poking needle length
Check for number of holes and positions
No poking of green tyres
Check for thr’ & thr’ poking
Poke the air traps
Bottom sttcher pressure
high Set it as per spec
Foreign maters Clean the foreign maters
Avoid deformaton, store them on rack and do not keep
Deformed green tyre
the green tyre one over the other
Old green tyre Green tyres are to be used on FIFO basis and consult Tech
Check for functoning and travelling of back / botom
sttcher
Improper functoning back Check gap between disk of back / botom sttcherf There
sttcher / bottom sttcher should not be any gap
Check the pressure
Check the back / bottom sttcher disks

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 Tread Defect

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 1. HEAVY RIND/ OPEN MOULD

POSSIBLE CAUSES ACTION

Check ply angle, if angle is high do not use the fabric &
Ply angle high
consult Tech
Drum set high Check the drum set and set it right
Shaping excess Check the shaping, set as per spec
Wrong moulding Check that correct tyre size going into respective mould
Check the gap and bring down top mould
Check the press alignment periodicallyf Check the
Gap between mould halves
lubrication system regularly
Check the closing force, if less, increase it
Check the ply applicaton, it should be crisscross
Parallel ply construction
Identfy the green tyre and scrap it
Mismatch of Bull gear Correct the position
Low platen temperature Check the temperature and set it as per spec

2. TREAD SEPERATION

POSSIBLE CAUSES ACTION

Ply angle low Check ply angle, if low then do not use and consult Tech
Tread length high Reject the treads
Tread gauge low Increase the gauges to spec values
Air trap under cushion Get them poked

Cured Tyre Defect Directory SKJ Page 23

 Ensure the biscuit roll usage at extruder
Check the cushion gauge at extruder, thinner cushion
gauge will lead to air traps
No ply perforation Ensure ply perforaton at calendering
Drum set low Check the drum set and set it as per spec
Off cantered tread Check the tread centering pointer and set it rights
Check for working of back / bottom sttcher
Check for back / bottom sttcher pressure
Ply / tread air entrapment Freshen the plies
Pat the treads by hand on side wall
Apply hand sttcher before botom sttcher application
C118 soluton not applied or
Check C118 soluton applicaton on tread base
dried
Check for poking needle length
Check for number of needle and rounds
No thr’ & thr’ poking
Check for thr’ & thr’ poking
Poke the air traps
Wet treads Mop the treads and remove water traces
Bottom sttcher pressure low Set it as per spec
Gap in back and botom
Get it corrected from Enggf Dept
sttchers when applied
Shaping improper Check the shaping, set as per spec
Mould temperature Set it as per spec
Check the gap and tighten the mould bolts
Gap in mould / platen
Check botom surface of the mould for warp nes
Steam trap not functioning Get it replaced
Twisted hose pipes Replace the hose pipe
Wrong curing cycle Check the curing cycle and set it right
Wrong curing steps Check every step’s tming and set it right
Check shaping pressure and set it right
Shaping is getng cut while Set the shaping ‘ cams ‘
loading Check pause height and time
Check any leakage through any valves
Blocked mould surface lines Clean all the air channels from the botom surface of the
on bottom surface mould

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 3. TREAD LAMINATION

POSSIBLE CAUSES ACTION

Contaminaton of FM in
Remove the foreign mater / reject the treads
treads
Polythene contaminated
Reeect the treads for refning / retread the green tyre
tread
Very old work-away used for
Reeect the treads and consult Tech
extrusion

4. HEAVY UNDER TREAD

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 POSSIBLE CAUSES ACTION
Check ply angle, if angle is high do not use the fabric &
Ply angle high
consult Tech
Tread gauge high Reduce tread gauges to spec values
Drum set high Check the drum set and set it right
Off cantered tread Check the tread centering pointer and set it rights
Check the ply applicaton, it should be crisscross
Parallel cords
Identfy the green tyre and scrap it
Check the shaping, set as per specf if required get it
Shaping excess
rectified
Wrong moulding Ensure right size in right mould

5. OPEN TREAD SPLICE

POSSIBLE CAUSES ACTION

Use tread stock as per specf (Which is released as OK by
Tread stock
Tech)
Tread length low Reject the tread
Improper tread skive surface
Correct the tread skive at extruder
cutting
Check tread splicing, it should match or it should be of-set
by 2 mmf, caution the tyre builders
Freshen the tread splice with naphtha
Improper tread splicing
Ensure C118 application
Side wall ends to be stretched and pressed one over the
otherf They should not be open
Hot knife sealing not done on
Hot knife to be used on tread splice for sealing
tread splice
Check whether tread splice is cemented or not
No tread splice pressing /
Get green tyres pressed
Cementing
Check tread splicing pressure and set it right
Check the shaping & set as per specf if required get it
Shaping excess
rectfed from Enggf Dept

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 Check the applicaton and concentraton of mould
Mould lubricant excess
lubricant
Foreign maters Clean the foreign mater
Avoid deformaton, store them on rack and do not keep
Deformed green tyre
the green tyre one over the other
Old green tyre Green tyres are to be used on FIFO basis and consult Tech

6. SPONGY TREAD

POSSIBLE CAUSES ACTION

Use tread stock as per specf (Which is released as OK by
Tread stock
Tech)
Check for porosity in the tread, if observed scrap the
tread
Tread porosity Check extrudate temp
Check Extruder feed strip supplyf (lack of material may
cause porosity)
Wet treads Mop the treads and remove water traces
Wrong moulding Check that correct tyre size going into respective mould
Check the leakage from the valve drain, vacuum, cold
Low HP steam
water return, hot water recovery
Check the functoning of HP supply valve and non-return
Delayed HP steam
valve
Mould temperature low Set it as per spec
Wrong curing cycle / short
Check the curing cycle and set it as per spec
cycle
Wrong curing steps Check every curing step and set it as per spec
Steam leak in mould Arrest the steam leak
Check the source from where water is coming on the
Moisture (water) in mould mould and arrest the leaks
Blow out the water from mould
Water is not fully drained
Check drain / vacuum operator
from bladder
Improper functoning of Check functoning of additonal drain valve and get it
additional drain valve rectified

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 Carcass Defect

Cured Tyre Defect Directory SKJ Page 28

 1. BUCKLED CARCASS

POSSIBLE CAUSES ACTION

Check ply angle, if angle is high do not use the fabric &
Ply angle high
consult Tech
Drum set high Check the drum set and set it right
Improper inner lube Apply inner lube on under cut of green tyre at bead region
applicaton Check for inner lube soluton concentraton
Vacuum high Check the vacuum and set it as per spec
Shaping less Set it as per specf, increase the shaping pressure
Avoid wrong moulding, check for correct size and
Wrong moulding
identification
Over life bladder Check the bladder condition and replace
Wrong bladder Ensure correct bladder usage
Bladder height off Check bladder height and set as per spec

2. PLY SEPARATION

POSSIBLE CAUSES ACTION

Fabric moisture high Check moisture percentage and consult Tech
No ply perforation Ensure ply perforation at bias cuter
Lack of fabric dip Ask to improve fabric dip
Dip coagulation Clean the rubber rollers at dipping unit
Do not use the fabric if freshening by naptha does not
Dry fabric
help

Cured Tyre Defect Directory SKJ Page 29

 Loose turn ups Caution the tyre builder
Wrinkled turn ups Caution the tyre builder
Identfy the air traps in plies and get them poked
Ply / ply air entrapment & no Ask builder to freshen the plies and apply the plies slightly
poking under stretch condition
Check the back / bottom sttcher pressure
Foreign maters Remove/ clean the FM embedded on plies

3. SPREAD CORDS

POSSIBLE CAUSES ACTION

Ply angle low Check ply angle, if low do not use the plies
Drum set lo Check the drum set and set it as per spec
Check for poking needle length
No thr’ & thr’ poking of green Check for number of needles and rounds
tyres Check for thru’ & thru’ poking
Poke the air traps
Check shaping pressure and set it right
Set the shaping ‘ cams ‘
Insufficient shaping pressure /
Check pause height and time
shaping delay
Check any leakage through any valves
Increase the shaping pressure if required

Cured Tyre Defect Directory SKJ Page 30

 4. LEAKY BLADDER

POSSIBLE CAUSES ACTION

Over life bladder Check the bladder condition and growth and replace it

Wrong bladder Ensure correct bladder usage

Check a pin hole leakage from bladder by giving shaping
Leaky bladder
and replace the same
Check the shaping, set as per spec
Check the blockages in pipelines, check drain / vacuum
Uneven shaping operaton, check HfPf fushing at end of cycle
Check piston seal leakage and remove the hydraulic
leakage
Missing allen bolts from Fix all allen bolts, otherwise bladder ‘T’ will slip from
bladder assembly assembly
Of centre loading Care to be taken while loading
Avoid deformaton, store them on rack and do not keep
Deformed green tyres
the green tyre one over the other
Poker needle in green tyre Remove the needle in the green tyre
Check the bladder ‘T’ positon in part nof 1,2 3 & 4f It
should ft properly in groove of clamping ring
Bladder assembly operation Clean the ‘T’ positon of part nof 1,2,3 & 4 where bladder
‘T’ is getting fixed
Check whether all allen bolts are present and tight
Inspect every bladder for blister / sepf, etcf defects, check
Bladder inspection
fash cutting at bladder ‘T’
Check water treatment at utlity for dissolved oxygen in
water
Bladder degradation
Check for any hydraulic leakage through cylinder in the
bladder and correct it

5. LOOSE CORD

Cured Tyre Defect Directory SKJ Page 31

 POSSIBLE CAUSES ACTION
No hot knife usage while ply Use hot knife while ply cutng / and flling of plies in a
cutting servicer
No removal of loose cord by Remove the cord while building
the builder while building
Cut the loose cord from green tyre

6. MISSING CORDS

POSSIBLE CAUSES ACTION

Defectve fabricf Remove the defectve fabric at bias cuter / building
Use pricker roll on 4-roll calender or do the operaton
Air traps at fabric calendaring
manually

Cured Tyre Defect Directory SKJ Page 32

 7. CARCASS CRACK

POSSIBLE CAUSES ACTION

Ply angle high Check ply angle, if angle is high do not use the fabric
Drum set high Check the drum set and set it right
Check the ply applicaton, it should be crisscross
Parallel cords while building
Identfy the green tyre and scrap it
Shaping excess Check the shaping, set as per spec
Wrong moulding Check that correct tyre size is going in respective mould
Check the gap in moulds by checking closing force, if less,
Gap between mould halves
then increase the closing force

Cured Tyre Defect Directory SKJ Page 33

 Other Defect

Cured Tyre Defect Directory SKJ Page 34

 1. SPONGY

POSSIBLE CAUSES ACTION

Vacuum low Check the vacuum pressure and set it as per spec
Low HP Check the leakage through the valve drain, vacuum, cold
water return, leakage from centre Mechanism, hot
water recovery
Low hot water Check the leakage from the valve drain, vacuum, cold
water return, hot water recovery
Drain operation Check drain operation
Check diaphragm sheet for leakage and replace
Check any blockage in line, replace
Check ID of hose pipe if it is less replace the same
Vacuum operation Check vacuum operation
Check diaphragm sheet for leakage and replace
Check any blockage in line, replace
Check ID of hose pipe if it is less replace the same
Gap in mould / platen Check the gap between mould / platen
Tighten the mould’s Allen bolts use sprit level for
proper levelling
Twisted hose pipes Replace the hose pipe
Wrong connecton of hose Check the hose connecton between main header and
pipes bladder inlet / outlet position and correct it
Wrong curing cycle Check the cycle and set it as per spec
Wrong curing steps Check the tming of all curing steps and set it as per spec
Leaky cold water supply valve Check the cold water supply valve and replace it
Piston seal leak Check for piston seal leak, if leaky, replace it

Cured Tyre Defect Directory SKJ Page 35

 2. TEMPERATURE FAILURE

POSSIBLE CAUSES ACTION

Check the instrument air pressure and inform utility
Instrument Air fail
Do not load the press if instrument air fails
Mould temp low Check the mould tempf and set it right as per spec
Check the gap between mould / platen
Gap in mould / platen
Tighten the mould’s Allen bolts
Trap not functioning Get it replaced from Enggf Dept
Wrong curing cycle Check the cycle and set it as per spec
Wrong curing steps Check the tming of all curing steps and set it as per spec
Steam leak in mould Arrest the steam leak check for pin holes
Warp moulds Do not use the mould for production and consult Tech
Platen inlet pipe leaks at entry
Arrest the steam leak
point of platen inlet
Increase the mould tempf to maximum for that round
Heavy leakage through leaky
bladder Close the inlet / outlet gate valve of that partcular cavityf
Where bladder is heavily leaking
Check whether master batch is used for tread extrusion, if
used, do not use the treads at all
Tread extruded with Master
Identfy the green tyres if treads being used and scrap
batch
them
Use only fnal batches okayed by Tech
Do not load the press immediately afer long breakdownf
Immediate press load afer Keep the press in close condition
breakdown Keep the press for atending the required mould temp
Check the tempf and then load the press

Cured Tyre Defect Directory SKJ Page 36

 3. LOW HP/HW

POSSIBLE CAUSES ACTION

Leaky bladder Replace the bladder
Check the leakage from the valve drain, vacuum, cold
Low hot water water return, leakage from Centre mechanism ,hot water
recovery
Check the functoning of HP supply valve and non-return
Delayed HP
valve
Check the instrument air pressure and inform utility
Instrument Air fail
Do not load the press if instrument air fails
Check HP operation
Check diaphragm sheet for leakage and replace it
HP operation
Check any blockage in line, replace
Check ID of hose pipe if it is less replace the same
Check HW operation
Check diaphragm sheet for leakage and replace
HW operation
Check any blockage in line, replace
Check ID of hose pipe if it is less replace the same

Wrong curing cycle Check the cycle and set it as per spec

Wrong curing steps Check the tming of all curing steps and set it as per specf
Leaky valve HWR Replace the leaky valve
Leaky valve shaping Replace the leaky valve
Leaky valve vacuum Replace the leaky valve
Leaky valve drain Replace the leaky valve
Leaky valve cold water Replace the leaky valve
Leaky valve CWR Replace the leaky valve
Instrument air pressure less Check air leakage on instrument air line circuits
Check the functoning of all solenoid valves, service them
Malfunctoning of solenoid or replace them
valves Check press closing positon, under close positon of press
lead to low air on programme air valve Rectify
Leakage through hydraulic Check and replace the same
Cured Tyre Defect Directory SKJ Page 37
 release and lower ring down
Diaphragm sheet

4. O-RING LEAK

POSSIBLE CAUSES ACTION

Inlet hose connecton gasket
Replace the gasket
lea
Take cold water test and replace the bottom ‘O’ ring
Bottom 'o' ring leak
Ensure correct size ‘O’ ring usage
Top ring raise / down hose
Replace the same
leaky
Cylinder head leak Rectify the same

5. TRIMMING DAMAGE

POSSIBLE CAUSES ACTION

Blunt trimming knife Sharpen the trimming knife or replace
Damaged teeth of trimming knife replace
Wobbling of trimming m/c Check the trimming machine alignment and set it right
Check whether tyres are bulge in nature
Check whether tyres are bent
Trimmer oriented Carelessness of trimmer can lead to trimming damages
hence caution the trimmer

Cured Tyre Defect Directory SKJ Page 38

 6. DE-SHAPED TYRES

POSSIBLE CAUSES ACTION

Pinched between arm and Check the arm roller setng; it should be at center wfrftf
bladder bladder assembly Set it right
No or missing rollers on arms Get them fixed
Tilted arm rollers, get them fixed horizontally
Check arm forward operaton and set it properly
Check lower ring operaton while tyre is getng lifed on
arms and set it right
Bladder bulging Check cold water circulaton, drain, and vacuum
operations
Check for any blockages in inlet / outlet pipelines
Ensure correct usage of cylinder head cap
Operator oriented Tyre is kept longer tme by the press operator in arm
pinched conditon so cauton the press operator & avoid it

7. UNDER CURE

POSSIBLE CAUSES ACTION

Gap in platen and mould Check the gap and tghten the mould’s Allen bolts

Cured Tyre Defect Directory SKJ Page 39

 Reject warped mould
Low mould temperature Set it as per spec
Check HP operation
Check diaphragm sheet for leakage and replace
HP operation Check any blockage in line, and remove the blockages
Check ID of hose pipe if it is less replace the same with
higher ID of pipe
Check HW operation
Check diaphragm sheet for leakage and replace
HW operaton
Check any blockage in line, replace
Check ID of hose pipe if it is less replace the same
Wrong curing cyclef Check the cycle and set it as per spec
Wrong curing stepsf Check the tming of all curing step and set it as per spec

8. OVERCURED

POSSIBLE CAUSES ACTION

Press does not open afer
Get it opened without delay
curing
a)Press over travelled and
Get it rectified
locked
b)Timer stuck up at the last
Inform maintenance Deptf and get it rectified
step
c)Malfunctoning of pressure
Inform maintenance Deptf and get it rectified
switch
Check drain and vacuum operaton and get it rectfed if it
d)Pressure in the bladder is not OK
High Mould temperature Set it as per spec
Wrong curing cycle Check the cycle and set it as per spec
Wrong curing steps Check the tming of all curing step and set it as per spec
Tyre remain in botom mould
Remove the tyre from the press with extra efforts
and gets over cure
Failures of lower ring raise
Rectfy the lower ring raise problem
operation

Cured Tyre Defect Directory SKJ Page 40

 9. FOREIGN MATERIAL CONTAMINATION

POSSIBLE CAUSES ACTION

Do not throw the green tyre on foor near building
machine or any other placef Keep them properly or stack
them on racks
Bad handling of green tyres
Shif the green tyre by lifing up from building machine to
conveyorf Do not roll them on floor
Keep minimum green tyre inventory
Damaged floor Repair the damaged foor surfaces as and when observed
Keep the area / foor clean all the tme where green tyres
Improper housekeeping
are going to be handled on floor for various operations
Improper green tyre cleaning Clean the green tyres properly before loading in the press
Engg Materials lying on the Remove the Enggf Materials from the area afer atending
floor to break downs

10. INNER PAINT CONTAMINATION

POSSIBLE CAUSES ACTION

Improper inner paint Apply inner paint on under cut of green tyre at bead
application region
Ensure that the paint applicaton is from bead to bead
inside the green tyre and not over the tyre
Check for inner paint soluton concentraton
Improper mould blowing While shaping, paint falls in the mould that is to be blown
out carefully by the operatorf Caution the press operator

Cured Tyre Defect Directory SKJ Page 41

 11. OFF MOULD REGISTER/ALLIGNMENT

POSSIBLE CAUSES ACTION

Check for correct ftment of mould halvesf Top and
botom indicaton marking on mould should match
Check for broken / bent dowel blocks of moulds and get
the corrected
Wrong mould ftment or Find the reason why mould is getng shifted and correct it
defective mould Tighten the mould’s Allen bolt properly
If misalignment is through out the circumference of the
tyre then only it can be rectfedf Check for the same
If alignment is matching at one side but not matching on
the other side, then it is a mould defect, consult Tech

12. NO PCI

POSSIBLE CAUSES ACTION

PCI pressure low Check the PCI pressure and set it as per spec
Tyre stuck to mould Mould lubricant to be spread periodically on the mould
Wrong PCI rim size Check the PCI rim size and get it replaced
PCI air connection Check the PCI pressure
Check the PCI connecton is from correct main line
Two connectons for each PCI rim

Cured Tyre Defect Directory SKJ Page 42

 About the Author

Mr Sunil Kumar Jagasia, B.Sc , LPRI , PGDOM , AMIRI , Member of RSDC , IPI ,QCFI
Auditor for ISO , Assessor for CII Exim bank .Having 43 years experience in Tyre Technology , Plastic
and composite recycled products.

He Joined LPRI Delhi in 1983 and then to Rajasthan Branch from day one as active members including
delivering Technical lectures for students, he has interest in making process / machine model for training
and writing books and manuals with total practical approach.