The Federal Aviation Administration (FAA) has expanded its emergency airworthiness directive to include the aging Douglas DC-10 aircraft following a serious engine pylon failure that was initially identified in the McDonnell Douglas MD-11F fleet. This decision comes just days after the grounding of the MD-11 freighter fleet due to the tragic crash of UPS Airlines Flight 2976 in Louisville, Kentucky, which resulted in the loss of all three crew members and several fatalities on the ground.
The FAA’s directive reflects rising concerns that similar design elements in the engine pylon structure could potentially expose the DC-10 to the same risks that led to the engine-pylon separation seen during the UPS flight. Consequently, operators of these older aircraft now face immediate inspections, possible grounding, and significant operational disruptions.
Background on the Engine Pylon Issue
The FAA’s actions follow the catastrophic accident involving UPS Airlines Flight 2976, where an engine and its pylon detached shortly after takeoff. The investigation into this incident prompted Boeing to advise all operators of the MD-11 freighter to suspend flights while thorough engineering assessments were conducted. As concerns escalated, it became clear that the DC-10, which has a long history of safety issues, shared critical design aspects with the MD-11, raising alarms about its structural integrity.
Following investigations, the FAA issued an emergency airworthiness directive that grounded all affected aircraft until they could undergo mandated inspections and any necessary repairs. According to data from FlightRadar24, the FAA determined that both the DC-10 and MD-11 exhibit sufficiently similar pylon design characteristics, thus posing equal structural risks.
Impact on DC-10 Operators
The implications of this expanded directive are immediate for the limited number of cargo carriers still operating the DC-10 and MD-11. Aircraft cannot operate until they have passed FAA-approved inspections of the pylons and associated structures. This directive will disrupt existing flight schedules and necessitate the rerouting of freight to other aircraft, which may incur contractual penalties if swift replacements cannot be arranged.
Moreover, maintenance organizations will need to mobilize experienced engineers and specialized tools on short notice, potentially straining resources already committed to other tasks. Increased scrutiny from insurers and lessors is anticipated, leading some operators to consider accelerating retirement plans for aging aircraft rather than investing in compliance measures for planes nearing the end of their operational lives.
In the short term, this directive tightens capacity for widebody freighters and raises operational costs. In the long run, it might expedite the phase-out of older tri-jets from active cargo service.
Why the FAA Took Action
The FAA’s decision was driven by a classic case of “common cause” concern, with preliminary investigations into the UPS accident indicating a critical failure in the left engine during a high-power takeoff. Given the shared type certificate and closely related pylon architecture of the MD-11 and DC-10, engineers quickly recognized the potential for widespread issues within the tri-jet family.
Emergency directives are issued in response to hazards that could compromise the safe operation of aircraft. The prospect of engine-pylon separation during takeoff presents a serious risk, prompting the FAA to err on the side of caution. By grounding the affected aircraft until their structural integrity is confirmed, the FAA aims to contain risks and devise long-term solutions once the root cause is fully understood.
As the situation develops, the aviation community will be closely monitoring the results of inspections and the potential for further regulatory measures to ensure safety in the skies.
