The National Transportation Safety Board (NTSB) has released its preliminary report on the deadly UPS cargo plane crash in Kentucky, shedding light on potential structural failures that contributed to the disaster. The crash, which killed 14 people — including three crew members and eleven on the ground — occurred during takeoff when the aircraft failed catastrophically.
Investigators identified fatigue cracks in a critical part of the aircraft known as the left pylon aft mount lug, which secures the engine to the wing. Additionally, the report notes “areas of overstress failure,” indicating that certain structural components fractured under excessive load. A spherical bearing outer race also showed circumferential fractures. These findings point to a structural failure that may have triggered the fatal accident.
According to the report, the aircraft’s taxi and initial takeoff roll were uneventful. However, during rotation — when the nose lifts for takeoff — the left engine and pylon detached from the wing. This separation caused a fire near the attachment point, and the plane briefly reached only about 30 feet above the ground before crashing into nearby industrial buildings, including a UPS warehouse and a petroleum recycling facility. Debris scattered across approximately 3,000 feet, causing extensive property damage.
The aircraft involved was a 34-year-old MD-11F, with approximately 21,000 flight cycles. Its last detailed inspection of the left pylon mount was in October 2021, and a recent lubrication task was completed just weeks before the crash on October 18, 2025. While inspections were up to date per the aircraft’s maintenance schedule, investigators are examining whether inspection protocols were sufficient to detect fatigue or stress cracks.
The preliminary findings draw historical parallels to American Airlines Flight 191 in 1979, in which a DC-10 lost its left engine and pylon during takeoff due to structural failure. Aviation safety experts are reviewing the MD-11 fleet to ensure that similar risks are mitigated. As a precaution, both UPS and FedEx have grounded their MD-11 fleets pending further inspections.
The NTSB emphasizes that this is a preliminary report. Flight recorders, maintenance logs, and additional structural components remain under examination. The final report, expected within a year or more, will provide definitive conclusions and recommend safety improvements to prevent future accidents.
This tragedy highlights the importance of rigorous aircraft maintenance and inspection schedules, particularly for older cargo planes with high flight cycles. The preliminary findings underscore potential vulnerabilities in aging aircraft structures and signal a critical moment for the aviation industry to review safety protocols and prevent similar disasters in the future.
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