How to Flat-Proof Your Gravel Bike

By Ryan Cook
Photos by Tannus America
November 25, 2024

Gravel cycling has taken the biking world by storm. I got into gravel riding about seven years ago after spending most of my life racing road and mountain bikes. From the very first ride, I was hooked. It felt like my road bike and mountain bike had a baby, and they named it "awesome."

Not only does gravel riding take you on roads you’d never otherwise explore, but it’s also safer. The dirt roads around my house see almost no traffic—usually just the occasional dude on a Surron. However, gravel biking isn’t without its challenges. Flat tires can quickly derail even the best rides, but the right gear can make all the difference.

Why Flat Tires Are the Enemy of Gravel Riders

Gravel biking demands tires that can handle sharp rocks, thorns, and unpredictable terrain. Traditional inner tubes are prone to punctures, often leaving riders stranded far from home.

When Flats Wreck a Ride

One of the worst moments I’ve had as a gravel rider was when a flat forced me to call my wife for a rescue. I was 80 miles away from home on a remote dirt road, with no cell service until I reached higher ground. By the time I got ahold of her, she had to drive for three hours on rough terrain to pick me up.

Fortunately, my wife is a saint, and she picked me up, and didn’t even make me sleep on the couch after that ordeal—but it was a wake-up call. I knew I needed a better solution. That’s when I started using Tannus Armour, and since then, I haven’t had to make another desperate rescue call.

Challenges of Tubeless Systems:

Tubeless systems can work well for small punctures, but they’re not foolproof.
Large gashes or punctures may still require a spare tube or complete tire replacement.

Garmin Unbound, When Tubeless Let Me Down

I signed up for and trained my butt off to do the Garmin Unbound race in Emporia, Kansas. I added extra sealant to my tires and brought a couple of bike tire plugs, but at mile 160, I got a flat that neither the sealant nor plugs could fix. Out came the spare tube, which got me to the next rest stop, where I luckily had another tire waiting.

That one sharp rock cost me at least 20 minutes. While tubeless systems are helpful, they’re not always the perfect solution for gravel adventures.

TANNUS ARMOUR

The Benefits of Tannus Armour for Cyclists

Tannus is an industry leader in anti-puncture solutions. They create inserts for nearly every type of bike and e-bike, using advanced foam technology to provide unmatched protection against punctures, snake bites, and sidewall tears (like the one I encountered at Unbound). After putting over 2,000 miles on my gravel bike with Tannus Armour, here’s what I’ve found:

Flat Protection: Never worry about flat tires on your gravel bike again.
Enhanced Durability: Perfect for long-distance rides over challenging terrain. I’ve got a tire with a 1.5-inch sidewall gash that I’m still using, thanks to Tannus Armour.
Comfort and Stability: Absorbs shocks for a smoother ride, even on rough surfaces. As someone with carpal tunnel syndrome, I’ve found the shock absorption to be a real lifesaver.

LEARN MORE ABOUT ARMOUR

Here’s how Tannus Armour compares to other flat-protection systems:

Flat-Protection Options for Gravel Biking

1. Tubeless Systems
- Works well for sealing small punctures.
- May fail for larger holes or gashes.
- Requires additional gear, like sealant, plugs, and a CO₂ pump.
2. Tubeless Plugs
- Effective for small-to-moderate punctures.
- The Stan’s Darts® have been my go-to option.
3. Tubeless Inserts
- Products like Tannus Tubeless®, CushCore®, and Vittoria Airliner® protect rims and improve ride quality.
- However, they’re more focused on performance enhancement and rim protection than flat prevention.

Additional Posts...

Keep It Public: The Fight for Our Public Lands

More than 3 million acres of U.S. public lands are at risk of being sold under a new Senate proposal and the outdoor community must act now. At Tannus, we believe public lands should remain wild, accessible, and protected for all. This isn’t about politics. It’s about preserving the trails we ride, the wilderness we explore, and the freedom to roam. Learn what’s at stake and how you can help stop the largest public land sell-off in modern history.
Winners Ride Tannus: Top Finishers at the 2025 Unbound Gravel Grand Prix Trusted Tannus Tubeless Inserts

At the 2025 Unbound Gravel Grand Prix, three of the top five finishers, including winner Cameron Jones, rode with Tannus Tubeless Inserts. From full Gravel setups to lightweight Lite configurations, Tannus delivered race-saving protection and podium-level performance. Discover why top gravel racers are choosing Tannus for their tubeless bike tires.
Title: Keegan Swenson on Crashes, Comebacks, and Why His Bike Probably Hates Him

What does it take to finish strong at Unbound Gravel 2025? According to pro cyclist Keegan Swenson: relentless resilience, sharp recovery, and the right gear choices, including when (and when not) to run tire inserts. In this exclusive post-race interview, Keegan shares how he overcame crashes, flats, and chaotic pack dynamics to secure a top-10 finish and maintain his lead in the Life Time Grand Prix. He breaks down lessons on race strategy, nutrition, positioning, and gear, including a no-fluff take on Tannus inserts, their role in gravel racing, and why he trains with them even when he doesn’t race with them. Whether you're an amateur rider or chasing marginal gains like a pro, this is your insider guide to what it really takes to thrive at Unbound.
National Bike to Work Day: Ride Like You Mean It (Without the Flats)

This National Bike to Work Day, join the 870,000+ Americans who are skipping traffic and pedaling in. Commuting by bike cuts stress, saves money, and boosts wellness, but nothing kills the ride faster than a flat tire.

That’s why smart commuters roll with Tannus Armour or Tannus Airless Tires, designed for e-bikes and traditional bikes alike. With 360° protection, shock absorption, and flat-proof tech, you can ride worry-free every day.

No flats, no stress. Just the ride.
The Origin of Solid: How Tannus Took on the Flat Tire and Won

Flat tires used to be the cost of admission for bike riders until Tannus rewrote the rules. This is the true story of how one frustrated engineer turned a deflated dream into a high-performance breakthrough: the world’s most advanced solid bike tire. From the invention of Aither foam to a 3,000+ mile airless ride, discover how Tannus took on the flat tire and built a no-maintenance, no-compromise solution that’s changing how riders roll, whether you're commuting, riding an e-bike, or managing a full fleet.