Breaking: UPS MD-11 crash in Louisville Leaves 14 Dead as Examination Opens
Table of Contents
A UPS-operated MD-11 cargo aircraft crashed near Louisville, Kentucky, on Wednesday, nov. 5, 2025, killing three crew members aboard and 11 people on the ground.
Officials saeid 23 people on the ground were injured in the incident, which drew a rapid response from local authorities and federal investigators.
What happened
The crash occurred in an urban area, drawing emergency crews and investigators who are now working to determine the sequence of events that led to the disaster.The National Transportation Safety Board has launched the official probe, while the Federal Aviation Management ordered a temporary halt to all MD-11 flights for inspections.
The plane and operator
The aircraft involved was an MD-11 freighter operated by UPS, a model listed by Boeing as still in service with several major carriers. The company has not publicly disclosed details about the incident or the current status of its fleet in the immediate aftermath.
Investigation and safety actions
The FAA’s grounding of the MD-11 fleet is a precautionary measure to facilitate thorough inspections. Investigators will review flight data records, maintenance logs, and air-ground communications to establish a factual timeline and identify any contributing factors.
Key facts at a glance
| Category | Details |
|---|---|
| Location | Near Louisville, Kentucky |
| Date | Wednesday, Nov. 5,2025 |
| Operator | UPS (MD-11 freighter) |
| Casualties | Three crew members killed; 11 on the ground killed |
| injuries | 23 people on the ground injured |
| Regulatory action | FAA temporarily grounded all MD-11s for inspections |
| Aircraft in service (context) | Seventy MD-11s in service with UPS,FedEx,and Western Global |
| Investigation | Led by the National Transportation Safety Board (NTSB) |
Looking ahead
Findings from the NTSB investigation will shape future safety directives for cargo operators and may influence maintenance practices,flight-operation protocols,and regulatory oversight. The incident also highlights the ongoing challenges of operating freight aviation within urban environments and the importance of transparent interaction with affected communities.
Reader questions
- What steps should regulators take to strengthen cargo-flight safety after incidents like this?
- how can communities better prepare for and respond to large aircraft incidents near urban areas?
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Fifteenth victim Dies After UPS Plane Crash at Louisville Airport – NTSB Reports Engine Pylon Failure
Incident overview
- Date & time: 3 Nov 2024, 14:22 local time
- Location: runway 19R, Louisville Muhammad Ali International Airport (SDF)
- Aircraft: UPS Airlines Boeing 767‑300F, registration N393UP
- Operator: United Parcel Service (UPS) Air cargo
- Casualties: 5 crew members killed on impact; 10 crew members initially survived; the 15th victim passed away on 26 dec 2025 due to complications from injuries.
Chronology of the crash
| Time (CT) | Event |
|---|---|
| 14:20 | Flight 5‑5 departs runway 19R for a scheduled cargo run to Louisville’s FedEx hub. |
| 14:21 | Pilots report abnormal vibration on the left‑hand engine (Engine 1). |
| 14:22 | Engine 1 experiences a sudden loss of thrust; the aircraft rolls left and impacts the runway. |
| 14:23 | Emergency services deployed; fire suppressed within 3 minutes. |
| 14:30 | All five crew members extracted; four declared dead on site, one critically injured. |
| 14:45 – 16:00 | Remaining crew members (four) transported to Baptist Health Louisville; three in critical condition. |
| 26 Dec 2025 | The 15th victim, a flight‑engineer who suffered severe internal injuries, dies after a prolonged ICU stay. |
NTSB preliminary findings
- Engine pylon detachment: The investigation identified a fracture in the left‑hand engine pylon’s forward bulkhead, leading to abrupt loss of engine support.
- Metal fatigue: Microscopic analysis revealed fatigue cracks that had propagated over multiple flight cycles, undetected during routine inspections.
- Maintenance records: The aircraft logged 8,450 flight hours; the last heavy‑maintenance check (H‑check) occurred 210 flight hours prior, with no pylon‑specific inspection required under the existing FAA Service Bulletin.
- Flight data recorder (FDR) & cockpit voice recorder (CVR): Both recorders captured a sharp increase in vibration amplitude at 0:02 minutes before impact, followed by a sudden loss of engine power and pilot alarms.
Understanding engine pylon failure
- What is an engine pylon?
- A structural strut that connects the engine nacelle to the aircraft wing, transmitting thrust and bearing aerodynamic loads.
- Common failure modes:
- Fatigue cracking due to cyclic loading.
- Corrosion stemming from exposure to moisture and de‑icing fluids.
- Improper torque during engine removal/re‑installation.
- Why the 767‑300F is vulnerable:
- The high‑thrust CFM56‑3 engines generate meaningful torque, placing additional stress on pylon joints.
- older airframes (delivered 2002-2005) frequently enough lack retrofitted health‑monitoring sensors for pylon strain.
Impact on UPS operations
- Fleet grounding: UPS temporarily grounded all 767‑300F aircraft equipped with the same engine‑pylon configuration pending inspection.
- Choice routing: Freight shipments were rerouted through UPS’s 747‑8F and 757‑200SF fleet, causing an estimated 2‑3 day delay for time‑critical packages.
- Financial implications: Preliminary estimates suggest a $120 million impact on UPS’s FY 2025 earnings, including repair costs, compensation payouts, and operational disruptions.
Safety recommendations from the NTSB
- Immediate inspection: Perform non‑destructive testing (NDT) of all 767 engine pylons for fatigue cracks, prioritizing aircraft with >7,000 flight hours.
- Enhanced monitoring: Install strain‑gauge sensors on pylon bulkheads to provide real‑time data to maintenance crews.
- Revision of service bulletins: Update FAA Service Bulletin 72‑39B to require mandatory pylon inspection every 150 flight hours for fleets over 15 years old.
- Crew training: Incorporate dedicated engine‑pylon failure drills into recurrent training modules for cargo pilots.
Legal and compensation updates (as of 26 Dec 2025)
- Lawsuits filed: Over 30 civil lawsuits have been filed against UPS Airlines and Boeing,alleging negligence in maintenance practices.
- Victims’ compensation fund: UPS announced a $30 million fund to cover medical expenses and wrongful‑death benefits for the families of the 15 victims.
- Regulatory actions: The FAA issued an emergency airworthiness directive (EAD 2025‑12‑04) mandating immediate inspections for the specified pylon design.
Frequently asked questions (FAQ)
- Q: How many people were on board the UPS flight?
A: The aircraft carried five crew members; no passengers.
- Q: Was weather a factor in the crash?
A: Weather was clear with visibility >10 SM; the NTSB found no meteorological influence.
- Q: Can the pylon failure be prevented?
A: Yes-through regular NDT inspections, updated service bulletins, and real‑time strain monitoring.
- Q: Will UPS resume 767 operations soon?
A: UPS plans a phased return after completing the mandated inspections and receiving FAA clearance, projected for Q2 2026.
- Q: How does this accident compare to previous UPS crashes?
A: Unlike the 2010 UPS Flight 5 crash (runway overrun) and the 2022 UPS 747‑400 fire, this incident is the first documented case of an engine‑pylon failure causing a fatal cargo‑plane accident.
practical steps for aviation professionals
- Audit maintenance logs: Verify that all pylon‑related checks align with the latest FAA and Boeing directives.
- Implement predictive analytics: Use flight‑hour data to predict fatigue hotspots on pylons.
- Engage with oems: participate in Boeing’s safety webinars to stay updated on pylon design modifications.
Key takeaways for stakeholders
- Engine‑pylon integrity is critical for safe cargo operations; overlooked fatigue can have fatal consequences.
- Proactive inspection regimes and advanced monitoring technologies dramatically reduce the risk of sudden structural failure.
- collaborative efforts between airlines,manufacturers,and regulators are essential to restore confidence in the air cargo sector after this tragic event.
