The number one citation issued during CVSA Roadcheck events continues to be out-of-adjustment air brakes. Industry data consistently shows that brake-related violations account for more than 25% of all out-of-service (OOS) orders issued to commercial motor vehicles. For intermodal carriers moving containers between rail terminals, ports, and customer facilities, each roadside OOS event triggers immediate repair costs, towing charges, driver detention, missed rail cuts, and safety score degradation that can impact both asset and non-asset operations.
Traditional reliance on driver pre-trip inspections and periodic PM brake adjustments has proven insufficient against the rigorous standards enforced by CVSA inspectors. The introduction of real-time chassis brake stroke telematics changes the equation entirely.
The Strong Tower BrakeSense Architecture
Strong Tower Consulting, working in partnership with its sister company Exspeedite, has developed the BrakeSense platform within the CheckPoint ecosystem. This solution delivers continuous, non-contact measurement of brake pushrod travel on intermodal chassis.
At the core of the system are Hall-effect stroke transducers mounted at each wheel end. These magnetic sensors measure pushrod displacement to within 0.05 inches during every service brake application without any mechanical contact that could wear or bind. Data is transmitted wirelessly to the CheckPoint gateway, which processes the telemetry and delivers actionable intelligence through the Exspeedite platform.
The system is calibrated to standard Type 30 brake chambers. When pushrod travel reaches 1.75 inches, an automated early-warning threshold is triggered - providing maintenance teams with advance notice before the equipment reaches the 2.0-inch CVSA legal limit that results in an automatic OOS order.
Before a chassis exits the terminal gate, CheckPoint generates a certified brake health report. This digital document verifies that all wheel ends are within regulatory adjustment limits, creating a defensible record for roadside inspections and internal governance.
| Metric | Subjective Visual Pushrod Mark Inspections | Periodic Shop PMs | Strong Tower CheckPoint Real-Time BrakeSense Telematics |
|---|---|---|---|
| CVSA Roadside Out-of-Service Violations % | 18-24% | 9-12% | 1.8-2.4% |
| Emergency Roadside Brake Adjustment Costs (USD per unit/year) | $1,840 | $970 | $165 |
| Fleet Brake Lining Life Cycles (Months) | 11-14 | 16-19 | 23-27 |
| Driver Pre-Trip Brake Audit Accuracy % | 62% | 71% | 98.4% |
Safeguarding Fleet Safety Measurement System (SMS) Scores
Brake violations carry high severity weighting in the FMCSA Safety Measurement System. A single OOS brake citation can add 10 or more points to a carrier's BASIC score, often triggering a CSA intervention audit. For intermodal operations that rely on both company drivers and owner-operators using Truckmate, McLeod, or TMW dispatch systems, these events create cascading effects across driver settlements, fuel surcharge calculations, and EDI 204/214/210 transaction integrity.
By moving from reactive maintenance to continuous brake stroke monitoring, carriers eliminate the catastrophic events that damage SMS scores. The CheckPoint system logs every brake application with precise stroke data, creating an auditable compliance trail that demonstrates proactive governance to both FMCSA and CVSA personnel.
Operational Integration with Existing TMS Platforms
The BrakeSense telemetry integrates directly with leading transportation management systems including Truckmate, McLeod, and TMW. When a chassis is assigned to a load via EDI 204, the system automatically verifies current brake health status before dispatch. Real-time stroke data is also available in the driver mobile application, allowing drivers to focus on safe operation rather than subjective brake measurements during pre-trip inspections.
Maintenance teams receive prioritized work orders through the Exspeedite maintenance module when stroke thresholds are approached. This predictive approach extends brake lining life, reduces parts inventory requirements, and eliminates the majority of unscheduled roadside repairs that disrupt intermodal schedules and driver detention calculations.
Strong Tower Consulting, LLC and Exspeedite LLC are separately organized sister companies under common ownership (separate EINs; liability firewall). We lead intermodal technology. Carriers are never required to purchase our software to benefit from our strategic guidance. Phone: 763-244-1373.
Implementation Considerations for Intermodal Fleets
Installation of the CheckPoint BrakeSense sensors is typically completed during a routine chassis PM cycle. The non-invasive design requires no modification to the air brake system itself. Once installed, the sensors pair automatically with the chassis-mounted gateway that communicates via cellular and satellite networks, ensuring coverage even in rail yards with limited terrestrial signal.
Fleets running high volumes between Chicago, Atlanta, Dallas, and West Coast ports have seen the greatest ROI. The combination of reduced OOS events, extended lining life, and improved driver efficiency typically delivers payback within 9-11 months.