FAA Grounds All MD-11 Aircraft After Tragic UPS Crash

By Garth Calitz

In a significant decision affecting the global cargo industry, the United States Federal Aviation Administration (FAA) has released an emergency airworthiness directive grounding all McDonnell Douglas MD-11 and MD-11F aircraft. This directive, declared on 8 November, comes in response to the fatal crash of a UPS Airlines MD-11F during take-off at Louisville International Airport on 4 November.

The FAA announced that it "has determined the unsafe condition is likely to exist or develop in other products of the same type design," leading to immediate inspections and corrective measures before any further flight operations can proceed. Although the regulator has not yet specified the exact technical issues needing attention, the grounding highlights significant concerns regarding the integrity of the MD-11's engine mounts and associated structural components.

The grounding order was prompted by the accident involving UPS Flight N259UP (manufacturer’s serial number 48417). Initial reports suggest that the aircraft’s left engine detached from the wing during the take-off roll, resulting in a loss of control and a crash near the end of the runway. The National Transportation Safety Board (NTSB) has initiated a comprehensive investigation to ascertain the cause of the structural failure.

Early speculation suggests a possible fatigue issue or structural fracture in the pylon assembly, but investigators have yet to confirm any mechanical root cause. The NTSB is working closely with Boeing, which inherited McDonnell Douglas’ designs following the 1997 merger, as well as UPS Airlines engineers and Pratt & Whitney, manufacturer of the aircraft’s PW4000 engines.

Before the issuance of the FAA directive, UPS Airlines and FedEx Express independently decided to ground their entire MD-11F fleets after discussions with Boeing. UPS emphasised that "safety is our top priority," and confirmed the suspension of MD-11F operations "out of an abundance of caution" until complete inspection results are available. FedEx, which has the largest MD-11F fleet globally, also confirmed a temporary halt in operations, stating that it will provide full cooperation with Boeing and federal investigators.

Western Global Airlines, one of the three remaining US operators of this type, has not made any public statements. Based in Florida, the airline operates a total of 18 aircraft, including 14 MD-11Fs, so the grounding essentially suspends the majority of its operations.

The McDonnell Douglas MD-11 debuted in 1990 as a long-range, three-engine successor to the DC-10. Although it no longer transports passengers, it remains significant in air freight due to its large capacity and long range. FedEx operates 58 MD-11Fs, UPS has 26, and Western Global manages 14. These companies collectively operate the majority of MD-11s still in service today.

For FedEx and UPS, the MD-11 accounts for less than 10% of their active fleets in terms of numbers, yet it remains vital for high-volume intercontinental cargo routes. Both companies have been progressively shifting to twin-engine widebodies like the Boeing 767-300F and 777F, which provide better fuel efficiency and easier maintenance. However, the current grounding is anticipated to temporarily impact capacity, especially with the busy holiday shipping season on the horizon.

The MD-11's design originates from the 1970s DC-10, which was involved in several notable accidents due to engine separations and pylon failures. Although these problems were resolved years ago through design changes and updated certification standards, the Louisville incident has brought up fresh concerns regarding the long-term structural durability of the ageing MD-11 airframe.

Given that many of these trijets have been operational for over 25 years, concerns regarding fatigue and corrosion in critical load-bearing structures are reasonable. The FAA's emergency grounding order suggests that the NTSB's preliminary investigation findings were significant enough to warrant precautionary actions for the entire fleet. The FAA has not indicated the duration of the grounding, but affected operators have already started thorough inspections with Boeing's guidance. Should the investigation reveal a systemic defect, additional airworthiness directives might be issued, possibly hastening the MD-11's expected retirement from active service.

For now, cargo carriers and regulators alike are focused on understanding exactly why the engine on N259UP failed so catastrophically. As one FAA official commented anonymously, “Until we know precisely what happened, we can’t risk another flight.” The coming weeks will likely determine the MD-11’s future in commercial aviation. Whether the venerable trijet returns to the skies or finally bows out for good, the Louisville accident serves as a stark reminder of aviation’s unyielding commitment to safety, no matter the operational cost.