Pilot reports his concerns about recent main landing gear brake failures on their CRJ-900 aircraft upon landing. Commonality of the brake failures are almost always just after a new brake has been installed. Pilot believes improper brake installation practices; which primarily include a failure to bleed the brake after installation have contributed to inoperative brakes.

Date: 2010-10 · Aircraft: Regional Jet 900 (CRJ900) · Phase: landing

Anomalies: aircraft-equipment-problem-critical

Synopsis

Pilot reports his concerns about recent main landing gear brake failures on their CRJ-900 aircraft upon landing. Commonality of the brake failures are almost always just after a new brake has been installed. Pilot believes improper brake installation practices; which primarily include a failure to bleed the brake after installation have contributed to inoperative brakes.

Narrative

Prior to the flight segment from ZZZ to ZZZ1; a thorough preflight inspection was completed with no defects noted. The cruise portion of flight was uneventful. Upon landing; I; the pilot flying; noticed what seemed like a decrease in brake efficiency. Once clear of the runway and during taxi to the gate; the BTMS (Brake Temperature Monitor System) was indicating clues as to why the brakes seem to be not as effective. The indications were brakes much hotter on the #1; #2;and #3 Main Landing Gear; however the #4 brake temperature was at zero. Suspicions at this point was a complete failure of that brake. Once at the gate and during my post flight inspection; it was apparent that the newly replaced #4 brake had indeed failed. The #3 brake was very hot; while the #4 brake was ice cold from flight; confirmed by actually touching the brake. Maintenance Control was contacted at that time. Some additional information: In addition to Maintenance Control; I also contacted the Director of Maintenance (DOM). I had a conversation with him about the brake fail. He is also aware of another brake fail incident in which I piloted an aircraft where both the number #1 and #4 brakes completely failed on [another] aircraft in ZZZZ earlier this summer. It is also a fact that the #4 brake had subsequent brake fails on flight segments that took place after. This should be documented in the Maintenance Logbook. When I spoke with the DOM; I expressed my deep concerns about this issue of brake failures. Luckily the incident in ZZZZ did not cause an accident or incident; although it took approximately three times the landing distance to safely stop the aircraft. Had I not had 13;000 FT of runway; which is unusually long; likely I would not have been able to stop on many of the much shorter runways in our system. On the same day; the next CRJ-900 aircraft I flew out of ZZZ1; had another brake issue during my next flight segments. Again; after a similar feeling in the brakes on landing [previously] in ZZZ1; I noticed some loss of brake efficiency. Also; similar indications however; a little different. All Brake Indications were as follows: #1; #2; and #4 brakes were at a brake temperature reaching '07' (224 degrees Celseus) and the #3 brake was at a '02' (64 degrees Celseus) this was an indication that the brake did not function well or little at all. Although I don't have the additional documentation of past events; these are not the only brake fail incidents I have come across. There is one very obvious commonality about the brake fails I have come across and that is; every time I do have a brake fail; it is almost always just after a new brake has been installed. I have discussed these brake issues with our Maintenance personnel both at our Carrier and at Carrier X (they also operate CRJ-900 aircraft). What I have learned about this brake issue is that improper brake installation practices which primarily include a failure to bleed the brake after installation; could cause a new brake to not function and fail. I have also learned that this is a short cut practice that may in fact be taking place here at our airlines.

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Source: NASA Aviation Safety Reporting System (public domain). Reports are voluntary submissions and are not verified by NASA.