BS AU 159g:2013

BSI Standards Publication

Specification for repairs to
tyres for motor vehicles
used on the public highway


BS AU 159g:2013

BRITISH STANDARD
Publishing and copyright information
The BSI copyright notice displayed in this document indicates when the document
was last issued.
© The British Standards Institution 2013
Published by BSI Standards Limited 2013
ISBN 978 0 580 75896 6
ICS 43.020; 83.160.10
The following BSI references relate to the work on this standard:
Committee reference AUE/3
Draft for comment 13/30249071 DC

Publication history
First edition, 1973
Second edition, November 1973
Third edition August, 1981
Fourth edition August ,1990
Fifth edition December ,1997
Sixth (present) edition, November 2013

Amendments issued since publication
Date

Text affected


BRITISH STANDARD

BS AU 159g:2013

Contents
Foreword
1
2
3
4
5
6
7
8
9
10

iii

Scope 1
Terms and definitions 1
Tyre performance 14
Tyre inspection before and during repair
Repair and tyres suitable for repair 14

Tyre inspection after repair 14
Marking 15
Repair materials 15
Sealants 15
Tube and inflation valves 15

14

Annexes
Annex A (normative) Initial inspection 16
Annex B (normative) Minor repairs to radial ply tyres for cars, commercial and
agricultural vehicles 18
Annex C (normative) Limits on or repairs for radial car tyres 19
Annex D (normative) Limits on major repairs for radial ply tyres for commercial
vehicles 22
Annex E (normative) Limits on repairs for radial ply tyres for agricultural
vehicles 24
Annex F (normative) Minor repairs to diagonal ply tyres for cars, commercial and
agricultural vehicles 25
Annex G (normative) Limits on repairs for diagonal ply car tyres 26
Annex H (normative) Limits on major repairs for diagonal ply tyres for
commercial vehicles 28
Annex I (normative) Limits on repairs for Diagonal ply tyres for agricultural
vehicles 29
Annex J (normative) Limits on minor repairs for motorcycle and scooter
tyres 30
Annex K (normative) Tyre repair preparation and building 31
Annex L (normative) Vulcanization 32
Annex M (normative) Repairs to inner tubes and inflation valves 33
Annex N (informative) Calculated values of repairable area of area T based on

nominal section width and percentage 36
List of figures
Figure 1 – Typical section of diagonal ply car tyre 5
Figure 2 – Typical section of radial ply car tyre 6
Figure 3 – Typical section of radial ply self supporting car tyre (SST) 7
Figure 4 – Typical section of diagonal ply commercial tyre 8
Figure 5 – Typical section of radial ply commercial vehicle tyre 9
Figure 6 – Typical section of diagonal ply agriculture tyre 10
Figure 7 – Typical Section of Radial Ply Agricultural Tyre 10
Figure B.1 – Repairable and non-repairable areas for penetration damaged
tyres 19
Figure C.1 – Repairable and non-repairable areas for radial ply car tyres 21
Figure C.2 – Typical sidewall damage for radial ply car tyres 21
Figure D.1 – Repairable areas for radial commercial vehicle tyres 23
Figure D.2 – Non-repairable area of radial ply commercial vehicle tyres (A to
B) 23
Figure D.3 – Typical Sidewall damage for radial ply commercial vehicle tyres 24
Figure E.1 – Repairable and non-repairable areas for penetration damaged
tyres 24
Figure G.1 – Repairable and non-repairable areas for diagonal ply car tyres 27
Figure I.1 – Repairable and non-repairable areas for diagonal ply tyres 29
Figure J.1 – Repairable and non-repairable areas for motorcycle and scooter
tyres 31
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BS AU 159g:2013

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Figure M.1 – Typical area damage for inner tubes 34
Figure M.2 – Typical split damage for inner tubes 34
List of tables
Table 1 – Load-capacity index (LI) 11
Table 2 – Speed symbols 13
Table B.1 – Repairable area of T as a percentage of the nominal section width of
tyre 18
Table B.2 – Radial tyre injury limits: size of penetration damage (after
preparation) 18
Table C.1 – Repairable areas T and WA)B) 20
Table C.2 – Radial car tyre injury limits (measured at the base of injury after
preparation) 20
Table D.1 – Commercial vehicle radial tyre injury limits (measured at base of
injury after preparation) 22
Table E.1 – Repairable areas T and WA)B) 24
Table E.2 – Agricultural vehicle radial tyre limits of repair (measured at base of
injury after preparation) 25
Table F.1 – Repairable area of T in terms of percentage of nominal width of tyre
A)B)
25
Table F.2 – Diagonal ply tyre injury limits: size of penetration damage (after
preparation) 26
Table G.1 – Repairable areas T and WA)B) 27
Table G.2 – Diagonal ply car tyre injury limits (measured at base of injury after
preparation) 27
Table H.1 – Repairable areas T and WA)B) 28
Table H.2 – Diagonal ply commercial vehicle tyre injury limits (measured at base

of injury after preparation) 28
Table I.1 – Repairable areas T and WA)B) 29
Table I.2 – Agricultural repair limits for diagonal ply tyres 29
Table J.1 – Motorcycle and scooter tyre injury limits (after preparation) 30
Table M.1 – Inner tube injury limits (after preparation) 33
Table N.1 – Calculated values for area T 36

Summary of pages
This document comprises a front cover, an inside front cover, pages i to iv,
pages 1 to 36, an inside back cover and a back cover.
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BRITISH STANDARD

BS AU 159g:2013

Foreword
Publishing information
This British Standard is published by BSI Standards Limited, under licence from
The British Standards Institution, and came into effect on 30 November 2013. It
was prepared by Technical Committee AUE/3, Renovation of tyres for motor
vehicles. A list of organizations represented on this committee can be obtained
on request to its secretary.

Supersession

This British Standard supersedes BS AU 159f:1997, which is withdrawn.

Information about this document
Repairs for limited run-flat tyres and temporary use spare tyres are not covered
by this British Standard. Repairs to inner tubes are covered, but repairs for
commercial vehicle steel diagonal ply tyres are not, as this type of tyre is
considered obsolete.
The 1973 edition of this British Standard specified the use of an inner tube to
repair very small penetrations in tubeless tyres. This method is not specified in
the 1981, 1990, 1997 editions or the present edition.
Good workshop practice for tyre repair is included in this British Standard, with
emphasis on conditions during vulcanizing to ensure that carcasses are cured in
the relaxed shape.

Presentational conventions
The provisions of this standard are presented in roman (i.e. upright) type. Its
requirements are expressed in sentences in which the principal auxiliary verb is
“shall”.
Commentary, explanation and general informative material is presented in
smaller italic type, and does not constitute a normative element.
Requirements in this standard are drafted in accordance with The BSI guide to
standardization – Section 2: Rules for the structure, drafting and presentation of
British Standards, subclause 11.3.1, which states, “Requirements should be
expressed using wording such as: ‘When tested as described in Annex A, the
product shall ...’”. This means that only those products that are capable of
passing the specified test will be deemed to conform to this standard.

Contractual and legal considerations
This publication does not purport to include all the necessary provisions of a
contract. Users are responsible for its correct application.

Compliance with a British Standard cannot confer immunity from legal
obligations.

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BS AU 159g:2013

1 Scope
This British Standard specifies requirements for the repair of diagonal ply and
radial ply pneumatic tyres for motorcycles, scooters, cars, commercial and
agricultural vehicles for use on the public highway. It specifies inspection
procedures, performance criteria, repair materials, and marking requirements,

for both tubed and tubeless tyres.
The repair of tubes and inflation valves is also covered.
This British Standard is not applicable to:
a)

tyres designed for use on pre-1933 vehicles, as their design and construction
can be unique and outside the range of tyres in current use;

b)

T-type temporary use spare tyres;

c)

temporary seals, i.e. externally inserted plugs, intended to allow the vehicle
to be driven for a limited period, until a permanent repair can be effected;

d)

use of liquid sealants introduced into tubed or tubeless tyres to aid the air
retention property (see Clause 9);

e)

tyres containing sealant gel; and

f)

specialist repairs carried out by the original tyre manufacturer.


2 Terms and definitions
For the purposes of this British Standard, the following definitions apply.
NOTE

2.1
2.1.1

Figure 1 to Figure 7 supplement the definitions given in this clause.

Structure
bias-belted tyre
pneumatic tyre of the diagonal ply type, with the carcass restricted by a belt
comprising two or more layers of inextensible cord material laid at alternate
angles not greater than those of the carcass
NOTE For the purposes of this British Standard, a bias-belted tyre may be treated as
a diagonal ply tyre.

2.1.2

diagonal ply tyre
pneumatic tyre in which the ply cords extend to the bead and lie at alternate
angles substantially less than 90° to the centreline of the tread

2.1.3

NOTE

Also known as cross ply tyre.

NOTE


The angle varies between manufacturers and applications.

radial ply tyre
pneumatic tyre in which the ply cords extend to the bead and lie at
approximately 90° to the centreline of the tread, the carcass stabilized by an
essentially inextensible circumferential belt

2.1.4

radial ply self supporting run flat tyre (SST)
pneumatic tyre in which the ply cords extend to the bead and lie at
approximately 90°to the centerline of the tread, the carcass stabilized by an
essentially inextensible circumferential belt
NOTE Such tyres have a specially reinforced sidewall to enable them to perform
when deflated. Limited in-service conditions might apply when run deflated, refer to
brand manufacturer.

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BS AU 159g:2013
2.1.5

BRITISH STANDARD
temporary use spare tyre

tyre intended only for temporary use, under restricted driving conditions, (e.g.
at high speeds or over a long distance) and of different type to those fitted for
normal driving conditions

2.1.6

T-type temporary use spare tyre
temporary use spare tyre designed for use in one position only at a time, with
inflation pressures higher than those for standard or reinforced tyres

2.2
2.2.1

Service
load-capacity index
numerical code associated with the maximum load a tyre can carry at the speed
indicated by its speed symbol
NOTE

2.2.2

See Table 1 and Table 2.

ply rating (PR)
index of tyre strength used to identify a tyre with its recommended maximum
permitted load when used for a specific service
NOTE

2.2.3


The ply rating does not necessarily represent the number of plies in a tyre.

service description
combination of a tyre’s load index and speed symbol
NOTE

2.2.4

See Table 1 and Table 2.

speed symbol
symbol indicating the speed at which a tyre can carry the load corresponding to
its load index or indices
NOTE

2.3
2.3.1

See Table 1 and Table 2.

Main components
bead
part of a pneumatic tyre shaped and structured to fit and hold the tyre to the
rim

2.3.2

bead heel
part of the bead that fills the angle formed by the junction of the rim flange
and the bead seat


2.3.3

bead toe
innermost part of the bead opposite the heel

2.3.4

belt
layer(s) of material(s) beneath the tread, laid in the direction of the tread
centreline, restricting the carcass in a circumferential direction (radial ply tyres
only)

2.3.5

breaker
intermediate ply between carcass and tread (diagonal ply tyres only)
NOTE

2.3.6

See also 2.3.13 protective breaker.

carcass
structural part of a tyre, not including the tread and outermost rubber of the
sidewalls, which, when inflated, bears the load on the tyre

2.3.7

chafer

material (in the bead area) used to protect the carcass against rim chafing

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2.3.8

BS AU 159g:2013
cord
textile or non-textile strands (threads) used in various components of the tyre

2.3.9

crown
area between the shoulders of a tyre

2.3.10

inner-lining
layer of rubber, from bead toe to bead toe, on the inside of the carcass
NOTE

2.3.11

In tubeless tyres the inner-lining has air-retaining properties.


ply
layer of rubber-coated parallel cords

2.3.12

protective breaker
optional strip of ply material between the tread and the belt, used to minimize
damage to the belt (commercial vehicle radial ply tyres only)

2.3.13

sidewall
part of a tyre between the tread and the bead

2.3.14

sidewall for self supporting tyres
specially designed sidewalls allowing limited tyre performance whilst in a
deflated state

2.3.15

sidewall rubber
rubber layer on the sidewall of the tyre and outside of the carcass, which may
include ornamental or protective ribs and fitting lines

2.3.16

shoulder

area between the sidewall and tread

2.3.17

tread
part of the pneumatic tyre intended to contact the road

2.3.18

tubeless tyre
pneumatic tyre designed for use without an inner tube

2.4
2.4.1

Tyre repair
buffing
mechanical preparation of a tyre surface(s) prior to application of
non-vulcanized material

2.4.2

combination plug-patch
shaped moulded unit combining a patch with a stem protruding from the centre
of the bonding face, used for the dual purpose of sealing and filling a
penetration in a tyre

2.4.3

patch

tyre or tube repair unit able to vulcanize to the inside of a tyre or outside of a
tube, with the object of sealing a penetration, and, if necessary, providing
reinforcement
NOTE

2.4.4

See 2.4.2 to 2.4.6

reinforced patch
patch containing material, in addition to rubber, often in the form of cords or
cables of textile or non-textile material, that impart additional strength while
maintaining ability to flex compatibly in normal service when vulcanized onto a
tyre carcass/inner liner

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2.4.5

BRITISH STANDARD
reinforced cross ply patch
type of reinforced patch in which the cords are oriented to align approximately
with the ply cords in a diagonal ply tyre


2.4.6

reinforced radial ply patch
type of reinforced patch in which the cords are oriented to align approximately
with the ply cords in a radial ply tyre

2.4.7

rubber only patch
patch containing no restricting or reinforcing cords, used for tube repairs and
minor penetration repairs in tyres

2.4.8

major repair
repair requiring a reinforced patch
NOTE

2.4.9

Major repairs are fully defined in Annex C, Annex D, Annex F and Annex G.

minor repair
repair requiring one of the following:
a) rubber only repair
b) combination plug patch
c) reinforced patch with penetration filler material

2.4.10


rubber
macromolecular material with the following properties:

2.4.11

a)

rapid return to the original shape, at room temperature, after substantial
distortion under weak stress; and

b)

resistance to permanent deformation by heat and moderate pressure

vulcanization
chemical transformation of rubber from the plastic to elastic state, by:
a)

heat and pressure for a given period; or

b)

natural process at room temperature [minimum 15 °C (59 °F)] over an
extended period, with or without pressure

NOTE

4

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Also known as curing.

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Figure 1

BS AU 159g:2013

Typical section of diagonal ply car tyre

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Figure 2

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Typical section of radial ply car tyre

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Figure 3

BS AU 159g:2013

Typical section of radial ply self supporting car tyre (SST)

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Figure 4

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Typical section of diagonal ply commercial tyre

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Figure 5

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Typical section of radial ply commercial vehicle tyre

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BRITISH STANDARD

Figure 6

Typical section of diagonal ply agriculture tyre

Figure 7


Typical Section of Radial Ply Agricultural Tyre

© The British Standards Institution 2013


45

46.2
47.5
48.7
50
51.5
53
54.5
56
58
60
61.5
63
65
67
69
71
73
75
77.5
80
82.5
85
87.5

90
92.5
95
97.5
100
103
106
109

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21

22
23
24
25
26
27
28
29
30
31

kg

Load

0

LI

Table 1

41
42
43
44
45
46
47
48
49

50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71

40

LI

145
150
155

160
165
170
175
180
185
190
195
200
206
212
218
224
230
236
243
250
257
265
272
280
290
300
307
315
325
335
345

140


kg

Load

Load-capacity index (LI)

81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
101
102
103

104
105
106
107
108
109
110
111

80

LI

462
475
487
500
515
530
545
560
580
600
615
630
650
670
690
710
730

750
775
800
825
850
875
900
925
950
975
1 000
1 030
1 060
1 090

450

kg

Load

121
122
123
124
125
126
127
128
129

130
131
132
133
134
135
136
137
138
139
140
141
142
143
144
145
146
147
148
149
150
151

120

LI

1
1
1

1
1
1
1
1
1
1
1
2
2
2
2
2
2
2
2
2
2
2
2
2
2
3
3
3
3
3
3

450

500
550
600
650
700
750
800
850
900
950
000
060
120
180
240
300
360
430
500
575
650
725
800
900
000
075
150
250
350
450


1 400

kg

Load

161
162
163
164
165
166
167
168
169
170
171
172
173
174
175
176
177
178
179
180
181
182
183

184
185
186
187
188
189
190
191

160

LI

4 625
4 750
4 875
5 000
5 150
5 300
5 450
5 600
5 800
6 000
6 150
6 300
6 500
6 700
6 900
7 100
7 300

7 500
7 750
8 000
8 250
8 500
8 750
9 000
9 250
9 500
9 750
10 000
10 300
10 600
10 900

4 500

kg

Load

201
202
203
204
205
206
207
208
209

210
211
212
213
214
215
216
217
218
219
220
221
222
223
224
225
226
227
228
229
230
231

200

LI

14
15
15

16
16
17
17
18
18
19
19
20
20
21
21
22
23
23
24
25
25
26
27
28
29
30
30
31
32
33
34

500

000
500
000
500
000
500
000
500
000
500
000
600
200
800
400
000
600
300
000
750
500
250
000
000
000
750
500
500
500
500


14 000

kg

Load

241
242
243
244
245
246
247
248
249
250
251
252
253
254
255
256
257
258
259
260
261
262
263

264
265
266
267
268
269
270
271

240

LI

46 250
47 500
48 750
50 000
51 500
53 000
54 500
56 000
58 000
60 000
61 500
63 000
65 000
67 000
69 000
71 000
73 000

75 000
77 500
80 000
82 500
85 000
87 500
90 000
92 500
95 000
97 500
100 000
103 000
106 000
109 000

45 000

kg

Load

BRITISH STANDARD
BS AU 159g:2013

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45

112
115
118
121
125
128
132
136

32
33
34
35
36
37
38
39

kg

Load

0


LI

Table 1

72
73
74
75
76
77
78
79

40

LI

355
365
375
387
400
412
425
437

140

kg


Load

Load-capacity index (LI)

112
113
114
115
116
117
118
119

80

LI

1
1
1
1
1
1
1
1

120
150
180

215
250
285
320
360

450

kg

Load

152
153
154
155
156
157
158
159

120

LI

3
3
3
3
4

4
4
4

550
650
750
875
000
125
250
375

1 400

kg

Load

192
193
194
195
196
197
198
199

160


LI

11
11
11
12
12
12
13
13

200
500
800
150
500
850
200
600

4 500

kg

Load

232
233
234
235

236
237
238
239

200

LI

35
36
37
38
40
41
42
43

500
500
500
750
000
250
500
750

14 000

kg


Load

272
273
274
275
276
277
278
279

240

LI

112
115
118
121
125
128
132
136

000
000
000
000
000

500
000
000

45 000

kg

Load

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Table 2

BS AU 159g:2013
Speed symbols
Speed
symbol

Speed

A1
A2
A3

A4
A5
A6
A7
A8
B
C
D
E
F
G
J
K
L
M
N
P
Q
R
S
T
U
H

≤5 (3)
≤10 (6)
≤15 (9)
≤20 (12)
≤25 (16)
≤30 (19)

≤35 (22)
≤40 (25)
≤50 (31)
≤60 (37)
≤65 (40)
≤70 (44)
≤80 (50)
≤90 (56)
≤100 (62)
≤110 (69)
≤120 (75)
≤130 (81)
≤140 (87)
≤150 (93)
≤160 (100)
≤170 (106)
≤180 (113)
≤190 (118)
≤200 (125)
≤210 (130)

V

≤240 (150)

W

≤270 (168)

Y


≤300 (187)

km/h (mph)

Load capacity reduction (V, W and Y tyres)
Speed
Load capacity
km/h (mph)

210 (130)
220 (137)
230 (143)
240 (150)
240 (150)
50 (156)
2260 (162)
270 (168)
270 (168)
280 (174)
290 (180)
300 (187)

100% of LI load
97% of LI load
94% of LI load
91% of LI load
100% of LI load
95% of LI load
90% of LI load

85% of LI load
100% of LI load
95% of LI load
90% of LI load
85% of LI load

NOTE 1 Tyres with ZR within the size marking and no other speed symbol are designed
for speeds in excess of 240 km/h (150 mph).
NOTE 2 Tyres with VR within the size marking are designed for speeds in excess of
210 km/h (130 mph).

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3 Tyre performance
Tyres repaired in accordance with this British Standard shall be able to operate
at their original speeds, loads and inflation pressures (service description).
NOTE Limits of repairable damage to car tyres, commercial vehicle tyres, motorcycle
tyres, scooter tyres, agricultural tyres, tubes, and valves, so that the tyres retain their
original speed capabilities or performance, are given in Annex A to Annex M.

4 Tyre inspection before and during repair

4.1 Tyres shall be removed from the associated wheel and thoroughly inspected
internally and externally, to determine suitability for repairing, in accordance
with the inspection requirements and damage limits in Annex A to Annex H as
applicable.
4.2 After injury preparation and before application of a patch or new rubber,
tyres shall be thoroughly re-examined to determine continued suitability for
repair.
4.3 Any existing repair shall be closely inspected, and, if the condition is found
to be unsatisfactory, removed and the damage assessed, in accordance with
Annex B to Annex H as applicable.

5 Repair and tyres suitable for repair
5.1 Damage assessed as detrimental to performance, and within the damage
injury limits given in Annex A to Annex H, shall be repaired in accordance with
Annex J, Annex K, and Annex B to Annex H as applicable.
5.2 Tyres damaged as described in Annex A and/or outside the injury damage
limits of Annex C to Annex H shall be rejected as unsuitable for repair.

6 Tyre inspection after repair
On repair, all tyres shall be thoroughly inspected to establish that they are
operating as they are intended, and to check that:
a)

repairs (including previous repairs) are free from defects and distortions that
might reduce performance capabilities;

b)

damage that could affect service life has been repaired; and


c)

major (reinforced) repairs have been marked in accordance with Clause 7.

For repairs vulcanized with heat, inspection shall be carried out within 30 min of
vulcanization.

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