NTSB: MD-11 engine-mount cracks led to UPS crash; FAA grounds MD-11s for inspections
The NTSB’s preliminary report and released photos/videos show the MD‑11’s left engine and pylon separating shortly after rotation after hidden cracks around boltholes in the left pylon’s aft mount propagated until both supporting arms snapped, igniting a fire and sending the airplane into a crash about 30 feet above ground that killed the three pilots and 11 people on the ground and injured 23 others. The FAA issued an Emergency Airworthiness Directive grounding all MD‑11/MD‑11F aircraft (and some related DC‑10s) — affecting UPS, FedEx and Western Global — until inspections and any repairs are completed; investigators noted the aircraft’s mounts were last examined in October 2021 and the cockpit voice recorder captured an alarm about 37 seconds after takeoff thrust was set.
📌 Key Facts
- The NTSB released a preliminary report and dramatic photos/video showing the MD-11’s left engine and pylon separating shortly after rotation, with the engine flying over the wing as fire erupted; the aircraft reached only about 30 feet above ground before crashing into a storage yard and two additional buildings.
- Investigators found fractures and hidden cracks in the left wing’s engine mount; the left pylon’s aft mount failed when both supporting arms snapped as cracks around boltholes propagated until failure under normal stress.
- The cockpit voice recorder captured an alarm bell about 37 seconds after the crew called for takeoff thrust.
- There were 14 fatalities (three pilots on board and 11 people on the ground) and 23 people were injured.
- The FAA issued an Emergency Airworthiness Directive grounding all MD-11/MD-11F aircraft until inspections were completed; affected operators (UPS, FedEx, Western Global) and some related DC-10s were parked pending inspections.
- The accident aircraft had not yet been due for a detailed inspection of those engine-mount parts — they were last examined in October 2021 and had roughly 7,000 cycles remaining before the next check.
- MD-11s represent roughly 9% of UPS’s fleet and about 4% of FedEx’s fleet, indicating a limited but operationally significant impact from the grounding.
- The NTSB noted a historical similarity to the 1979 American Airlines Flight 191 engine/pylon separation; UPS Airlines President Bill Moore said the company will work with investigators to identify the cause and define inspection and repair plans before returning aircraft to service.
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📰 Sources (3)
- NTSB released a preliminary report and dramatic sequence of photos showing the left engine separating and flying over the wing as fire erupted; the aircraft reached only about 30 feet AGL before crashing.
- Investigators found evidence of fractures in the left wing’s engine mount; the aircraft was not yet due for a detailed inspection of those parts—last examined in October 2021 with roughly 7,000 cycles remaining before the next check.
- Cockpit voice recorder captured an alarm bell about 37 seconds after the crew called for takeoff thrust.
- Fatalities specified as three pilots on board and 11 people on the ground near the UPS Louisville hub.
- Scope/context of grounding noted: all MD-11s at UPS, FedEx, Western Global (and some related DC-10s) parked pending inspections; MD-11s comprise ~9% of UPS’s fleet and ~4% of FedEx’s.
- UPS Airlines President Bill Moore said the company will work with investigators to identify the cause and then define inspection/repair plans before returning aircraft to service.
- FAA issued an Emergency Airworthiness Directive grounding all MD-11/MD-11F aircraft until inspections were completed.
- Surveillance video sequence: left engine and pylon separated shortly after rotation; engine fell to the ground; fire ignited near the left pylon attachment and continued until impact.
- Technical detail: the left pylon’s aft mount failed when both supporting arms snapped; hidden cracks around boltholes propagated until failure under normal stress.
- Injury update: 23 people were injured in addition to the 14 fatalities.
- Historical context: NTSB notes similarity to the 1979 AA Flight 191 engine/pylon separation at Chicago O’Hare.
- Impact details: aircraft crashed into a storage yard and two additional buildings.