LOUISVILLE, Ky. — Federal investigators said Thursday they found fractures in the mounts for the engine that separated from a UPS plane as it attempted to take off before crashing.
The cargo plane for the Sandy Springs-based company crashed Nov. 4 near Louisville’s Muhammad Ali International Airport, killing the three crewmembers on board and 11 people on the ground. Another 23 people were injured.
The National Transportation Safety Board also released photos in its report showing the engine flying off. Investigators said there was evidence of cracks in the left wing’s engine mount.
The MD-11 plane only got 30 feet (9.1 meters) off the ground, the NTSB said, citing the flight data recorder in its first formal but preliminary report about the Nov. 4 disaster in Louisville, Kentucky.
The NTSB said the plane was not due yet for a detailed inspection of key engine mount parts that had fractures. It still needed to complete nearly 7,000 more takeoffs and landings.
It was last examined in October 2021.
“It appears UPS was conducting this maintenance within the required time frame, but I’m sure the FAA is now going to ponder whether that time frame is adequate,” aviation safety expert Jeff Guzzetti told The Associated Press after reading the report.
It’s not clear when the cracks started to develop on the 34-year-old plane and whether they could have been missed in that earlier inspection. Another aviation expert, John Cox, described fatigue cracks as “normal wear and tear on an aircraft.”
He said a metal part, like the engine mount that vibrates every time the plane flies, will eventually develop cracks. Cox noted it’s just a question of how often those parts need to be inspected and what maintenance is required.
The NTSB report revealed the first new details since board member Todd Inman briefed reporters on Nov. 7. He said the cockpit voice recorder captured an alarm bell going off about 37 seconds after the UPS crew called for takeoff thrust.
“It’s one thing to be involved in a natural disaster and another thing to be involved in a man-made, human error tragedy, and that’s what we believe this is,” said Sean Garber, who looked at the report and whose auto salvage yard near the airport took a direct hit.
All MD-11s used by UPS, FedEx and Western Global — along with a few related DC-10s — were grounded after the crash until they can be inspected and repaired, but the Federal Aviation Administration hasn’t said what will be required.
Cox said those air carriers “are going to have to make some hard decisions” because they were already planning to retire the planes in the next few years.
“If you have to pull the engines off and do some sort of visual inspection or replacement, that’s going to run into a significant cost,” he said.
MD-11 aircraft make up about 9% of the UPS fleet and 4% of the FedEx fleet, the companies have said.
Earlier this week, Bill Moore, president of UPS Airlines, an arm of UPS, said the company is working with investigators to determine the key cause of the crash.
“Once we determine that, then they’ll be able to develop an inspection plan,” Moore said at a news conference in Louisville. “Can we inspect it? If so, how do we repair it? How do we put it back together? And then eventually return the fleet to service. But that’s not going to happen quickly.”
Guzzetti said photos of this crash appear strikingly similar to the way the same engine came off an American Airlines plane in 1979, causing a crash that killed 273. But the NTSB report makes clear that a different part failed in Louisville.
Improper maintenance caused the Chicago crash when mechanics used a fork lift to lift the engine back up, the NTSB said.
The Associated Press contributed to the report.
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