Nearly 1.17 billion weigh station bypasses between 1997 and January 2026 has saved fleets nearly $12.5 billion in operational cost savings, according to PrePass Safety Alliance’s inaugural Mile Marker report—a new annual series that quantifies the national impact of weigh station bypass technology on key fleet operational indicators.
Those indicators include drive time, fuel use and CO2e emissions.
According to the report, weigh station bypass saves seven minutes of drive time, half a gallon of fuel, $10.65 in operational costs, and 0.00509 metric tons of Co2e emissions per bypass.
Over nearly 30 years, that has totaled nearly 136.5 million driver hours—comparable to two million workweeks; 584.9 million gallons of fuel—or one year’s worth of gas for 3.8 million passenger vehicles; more than $12.4 billion in operational cost savings; and over 1 million metric tons of CO2e emissions – equivalent to removing 225,000 passenger vehicles from the road for one year.
PrePass offers a formula to help fleets calculate how weigh station bypass impacts fuel savings.PrePass Safety Alliance
The other benefit is safety.
“By allowing compliant fleets to bypass inspection sites, enforcement can focus on higher-risk vehicles, resulting in more targeted inspections, fewer delays, and a better use of resources,” the report states. “When low-risk trucks keep moving, roads become more predictable, less congested, and ultimately safer, not just for commercial drivers, but for passenger vehicles and first responders as well.”
The new report aims to provide a national perspective on the factors influencing safety and efficiency to help fleets, policy makers, and enforcement officials prioritize improvement, investment, and long-term planning.
“While states typically track outcomes independently, Mile Marker 2026 brings these datasets together, revealing opportunities that only emerge when we look at the bigger picture,” the report said. “By unifying years of regional data, we’ve created a national benchmark to inform smarter decisions, strengthen enforcement strategies, and demonstrate the value of effective public-private partnership.”
The report noted that mobile-based bypass is opening new opportunities for both states and carriers, offering faster implementation, lower infrastructure costs, and expanded access to screening across a broader range of locations.
