Military Run Flat Inserts —
Mobility that survives the worst mile.
A run flat insert is a structural polymer device inside the tire that carries the vehicle when the tire can't. Ours is a three-segment antiballistic polymer run flat insert — engineered for the armored vehicle market, and built to outperform traditional one-piece rubber. Up to 100 km of run-flat mobility after full deflation.
What Are Run Flat Inserts?
A run flat insert is a structural device installed inside a pneumatic tire that allows a military vehicle to continue driving after the tire loses air pressure. When a tire is punctured — whether by ballistic damage, roadside debris, or terrain hazards — the run flat insert takes over the load-bearing function that air pressure normally provides. It supports the tire's inner crown, prevents the sidewalls from collapsing, and keeps the tire bead firmly seated on the wheel rim.
Without a run flat insert, a deflated tire collapses under the vehicle's weight within seconds. The tire shreds, the bead unseats from the rim, and the vehicle is immobilized — often in a combat zone or hostile environment where stopping is not an option. A properly installed run flat insert changes that equation entirely. It transforms a mission-ending flat tire into a manageable event, giving the crew time and distance to reach safety or a maintenance point.
The Toota Group's run flat inserts are manufactured from antiballistic polymer — an advanced engineered material that is significantly lighter than traditional rubber or steel alternatives. Each insert is composed of two or three segments that bolt together around the wheel rim, creating a continuous load-bearing ring inside the tire. This segmented design is the key to the system's field-serviceability: segments can be installed, inspected, or replaced with standard hand tools, without the need for hydraulic presses or specialist fitting equipment.
Static vs Dynamic Run Flat Inserts
Not all run flat inserts are the same. The Toota Group offers two distinct systems, each engineered for specific wheel types and operational requirements. Understanding the difference ensures you specify the right insert for your platform.
Static Run Flat Inserts
Designed for multi-piece (bolt-together) military wheels — the standard on heavy armor and tactical platforms like the HMMWV, FMTV, and MRAP. Three antiballistic polymer segments bolt around the wheel rim. The beadlock function is particularly strong: even fully deflated tires do not rotate on the rim. Available in Static 50 (50 km range) and Static 100 (100 km range) configurations. Field-serviceable with standard tire equipment. 10+ year service life.
Static RunFlat Details ▸Dynamic Run Flat Inserts
Designed for single-piece wheels — one of the most globally utilized run flat insert systems. Two or three antiballistic polymer segments with a patented locking design that requires no specialist tools. Delivers smooth, vibration-free performance at highway speeds during normal driving. Available in Dynamic 15 (15 km), Dynamic 50 (50 km), and Dynamic 100 (100 km) configurations. Compatible with CTIS (Central Tire Inflation System) equipped vehicles.
Dynamic RunFlat Details ▸Materials, Weight & Load Ratings
The Toota Group's run flat inserts are engineered to meet the demanding requirements of modern tactical vehicle operations. Here are the key technical parameters that define their performance.
| Specification | Toota Polymer Run Flat Insert | Industry Context |
|---|---|---|
| Material | Antiballistic engineered polymer — segmented construction | Traditional rubber or steel one-piece designs |
| Weight Savings | ~15% lighter than comparable run flat inserts | Heavier unsprung weight per wheel position |
| Construction | 2 or 3 bolt-together segments with locking mechanism | Single-piece press-fit designs |
| Installation | Hand tools only — torque wrench and standard shop equipment | Typically requires hydraulic press or dedicated fitting machine |
| Run-Flat Range | Up to 100 km on road after full deflation | 30–50 miles (48–80 km) typical for comparable systems |
| Service Life | 10+ years — polymer does not perish over time | Rubber components may degrade with age and exposure |
| Reusability | Fully reusable — transfer between wheels, inspect and reinstall | Some systems are single-use or require factory reconditioning |
| Ballistic Protection | Antiballistic rated — tested across all temperature ranges | Varies by manufacturer and material |
| Temperature Range | -40°C to +70°C operational | Standard military temperature envelope |
| Recyclability | Material reclaimable — can be recycled into new products | Limited end-of-life options for rubber-based systems |
Compatible Military Vehicles
The Toota Group's run flat inserts are specified per wheel and tire size, making them compatible with virtually every tactical wheeled vehicle in service today. Here are the primary platforms supported.
HMMWV (Humvee)
The High Mobility Multipurpose Wheeled Vehicle is the most widely deployed light tactical vehicle in the world. Toota run flat inserts are available for all HMMWV wheel configurations, including the standard 16.5-inch and 17-inch rim variants. Both static and dynamic systems are supported depending on wheel type.
JLTV
The Joint Light Tactical Vehicle is the HMMWV's successor, with higher payload and protection requirements. Toota run flat inserts are engineered to meet JLTV's increased gross vehicle weight rating while maintaining the weight savings and field-serviceability that fleet managers demand.
FMTV
The Family of Medium Tactical Vehicles encompasses 2.5-ton and 5-ton cargo trucks that form the backbone of Army logistics. Run flat inserts for FMTV platforms are specified for the larger tire sizes and higher load ratings these vehicles require.
MRAP
Mine-Resistant Ambush Protected vehicles carry heavy armor and operate in the highest-threat environments. Toota's antiballistic polymer run flat inserts are purpose-built for the MRAP's weight class, providing sustained mobility after ballistic tire damage.
Hand-Tool Installation — No Specialist Equipment
One of the defining advantages of the Toota Group's segmented polymer run flat inserts is the installation process. Unlike traditional one-piece run flat inserts that require a hydraulic press and dedicated fitting machinery, our three-segment design bolts together around the wheel rim using standard hand tools.
The process is straightforward: the three polymer segments are positioned around the rim, the locking bolts are torqued to specification, the RunFlat lubricant is applied to the inner tire surface, and the tire is mounted. The entire procedure can be performed in a motor pool, at a forward operating site, or at our Freehold, NJ facility — wherever the vehicles are.
- No hydraulic press required — segments bolt together with a torque wrench.
- No fingers inside the tire during fitting — safer for your crew.
- Field-serviceable — unbolt to inspect, service, or transfer between wheels.
- Install where the vehicles are — motor pool, forward site, or our facility.
Run Flat Inserts vs Foam Fill vs Beadlocks
Three technologies compete for the military run-flat mission. Here's how they compare across the metrics that matter to fleet managers and procurement officers.
| Capability | Run Flat Inserts (Toota Polymer) | Foam-Filled Tires | Beadlock Wheels |
|---|---|---|---|
| Run-Flat Distance | Up to 100 km | Unlimited at low speed; degrades at highway speed | Zero — tire collapses without air |
| Weight per Corner | Lightest option — ~15% lighter than comparable inserts | Heaviest — foam adds substantial unsprung mass | Moderate — mechanical clamp ring adds weight |
| Reusability | Fully reusable — transfer between tire changes | Single-use — entire assembly replaced when tire wears | Reusable — but provides no run-flat capability |
| Highway Performance | Smooth, vibration-free at highway speeds | Heat buildup at speed degrades foam | Normal highway performance when inflated |
| Field Serviceability | Hand-tool install — serviceable in theatre | Requires pumping equipment and cure time | Mechanical — but does not solve the run-flat problem |
| Lifecycle Cost | Lowest TCO — reusable across multiple tire sets | Highest — entire wheel assembly replaced each cycle | Moderate — but requires separate run-flat solution |
For the vast majority of military applications, polymer run flat inserts offer the best combination of mobility, weight, and lifecycle economics. Foam fill may be appropriate for specialized low-speed vehicles in extreme puncture environments. Beadlock wheels are best understood as a complement to run flat inserts — they keep the tire on the rim at low pressure but provide zero mobility after a full deflation.
NSN Numbers & DLA Procurement Path
The Toota Group's run flat inserts and supporting products are NSN-assigned and available through the Defense Logistics Agency (DLA) supply chain. This means procurement officers can order through established government channels without the friction of a sole-source justification.
- NSN 2640-01-563-1421 — Runflat kit / run flat insert assembly.
- NSN 2640-01-419-6200 — Toota RunFlat Lubricant, 11.5 fl oz tube.
- NSN 2640-01-457-5552 — Toota RunFlat Lubricant, 55-gallon drum.
- CAGE 93ST9 — Registered and active in SAM.gov. Ready for award.
- DLA Internet Bid Board System (DIBBS) — Search CAGE 93ST9 for open solicitations.
Whether you're ordering through DLA, GSA, or a direct purchase order, the procurement path is established. We support both domestic requirements and Foreign Military Sales (FMS) cases. Contact us with your solicitation number for a fast turnaround on your quote.
CAGE 93ST9 — A Defense Supplier You Can Count On
The Toota Group is a verified, active government contractor with the credentials that procurement officers look for. No competitor on page one of Google for "run flat inserts" has a CAGE code — this is a unique differentiator that signals we are a legitimate, vetted defense supplier.
CAGE 93ST9
Commercial and Government Entity code assigned by the Defense Logistics Agency. Active and verified in SAM.gov. This is your assurance that The Toota Group is a recognized, auditable supplier in the federal procurement system.
SAM.gov Registered
Full System for Award Management registration — active and current. We can receive contract awards, purchase orders, and government credit card payments through the standard federal procurement infrastructure.
JCP Certified
Joint Certification Program — Level 2 Self-Assessment. Authorized to access unclassified military technical data and specifications. This certification is required for suppliers working with military drawings and technical data packages.
Small Business
Certified small business based in Freehold, New Jersey. Helps your agency meet small business set-aside goals while getting the run flat inserts and wheel assemblies your fleet needs.
One Vendor. The Complete Corner of the Vehicle.
The Toota Group is unique in the defense supply chain: we don't just sell run flat inserts. We supply everything that goes on the corner of a tactical vehicle — from the run flat insert to the mounted, torqued, CARC-painted wheel assembly on a pallet.
Run Flat Inserts
Static and dynamic polymer run flat inserts — the core of our product line. Up to 100 km run-flat mobility, hand-tool installable, NSN-supported.
View RunFlats ▸RunFlat Lubricant
Long-life grease that cuts friction between tire and insert during run-flat operation. Available in 11.5 fl oz tubes and 55-gallon drums. NSN-assigned.
View Lubricant ▸Wheel Assemblies
Complete single and two-piece wheel assemblies — rim, run flat insert, lubricant, and tire — mounted, torqued, and delivered ready to bolt on.
View Assemblies ▸Military-Grade Tires
General, Continental, Michelin, Goodyear, Carlisle, and more — truck, trailer, and specialty tires for military trailers and support fleets.
View Tires ▸Inside the wheel.
From the vehicle to the tire to the three-piece polymer RunFlat inside — in 28 seconds.
Built for the mission.
Military vehicle driving on Toota polymer RunFlats — mission-ready mobility in action.
Turn it. Zoom it. Take it apart.
This is the three-piece polymer RunFlat on its rim. Drag to rotate, scroll or pinch to zoom, and slide to explode the assembly.
A polymer ring that carries the load when the air is gone.
Three antiballistic polymer segments bolt around the wheel rim inside the tire. Under normal driving they're along for the ride. The moment the tire loses pressure — from ballistic damage, terrain, or sabotage — the RunFlat becomes the load path, keeping the tire on the bead and the vehicle under the driver's control.
- Keeps the driver in control after ballistic or terrain-related tire damage.
- Holds the bead so the deflated tire stays seated at speed and under maneuver.
- Polymer, not rubber — less unsprung mass at every corner of the vehicle.
- Field-serviceable — unbolts for inspection or replacement on site.
Why segmented polymer.
Segmented polymer construction delivers advantages a comparable insert can't — at every corner of the vehicle.
Lighter Corner Weight
Roughly 15% lighter than comparable alternatives. Multiply that across every wheel position and you get back payload, fuel economy, and suspension life.
Faster to Field
Bolt-together segments install with hand tools — no specialist fitting equipment, no shipping wheels out and waiting.
Built for Armor
Antiballistic polymer designed for the armored and security vehicle market — protection engineered in, not just mass added on.
Serviceable, Reusable
Unbolt to inspect, service, or transfer between wheels. A segmented system is an asset you maintain, not a consumable you press in once.
Not a stock photo. Our floor.
Polymer RunFlat segments staged and palletized at our New Jersey facility, ready to install or ship.
The unsung hero of run-flat range.
When a tire runs deflated, it drags against the insert and generates serious heat. Our long-life RunFlat grease goes in at installation and slashes that friction — protecting the tire, protecting the insert, and extending how far you can actually drive on a flat.
- Long-life grease formulation — stable under sustained run-flat heat.
- Applied once, at install — no in-service maintenance.
- Protects both components — tire carcass and polymer insert.
- Available with every RunFlat order — or supplied separately for your existing fleet program.
Buy it by the tube or the drum.
Toota RunFlat Lubricant is available on its own — not just with our systems. Whether you're topping off a single install or supplying a whole fleet program, order the size that fits.
Run Flat Lubricant
Applicator Tube
11.5 fl oz (340 mL) · Standard cartridge
Alternate item to NSN: 2640-01-419-6200
$49.99
Perfect for single installs and field top-offs. Fits a standard caulk gun for controlled application.
Request a Quote
Run Flat Lubricant
55-Gallon Drum
55 U.S. gallons · Bulk fleet supply
Alternate item to NSN: 2640-01-457-5552
$7,049.00
Bulk long-life grease for depots, assembly lines, and fleet-wide programs. Volume pricing available.
Request a QuoteGovernment & volume orders welcome — CAGE 93ST9. Request a quote or call (848) 444-1195.
Sized to your platform.
RunFlat systems are specified per wheel and tire size. Send us your platform, rim size, and tire spec — we'll match the right system and quote it, standalone or as part of a complete wheel assembly.
RunFlat FAQ
How far can a vehicle drive after losing tire pressure?
With the system fitted and lubricated, up to 100 km of continued mobility is achievable following ballistic or terrain-related deflation — enough to leave the threat area and reach support, not just limp to the shoulder.
Do we need special equipment to install these?
No. That's the point. The three polymer segments bolt together around the rim with standard hand tools and a torque wrench. See the interactive installation walkthrough.
How much weight does polymer save?
Typically around 15% versus a comparable runflat — and that's rotating, unsprung mass, where weight savings pay off most in handling, fuel, and component life.
Is the lubricant required?
Strongly recommended. Run-flat operation generates friction heat between tire and insert; the long-life RunFlat grease is what keeps that heat from destroying the tire early and cutting your run-flat range short.
Can Toota supply the complete wheel — not just the insert?
Yes. We build complete single and two-piece wheel assemblies — rim, RunFlat, lubricant, and tire — mounted, torqued, optionally CARC-painted, and delivered ready to bolt on.
Spec a RunFlat for your platform.
Send your rim and tire sizes — we'll respond with a matched system and pricing.