Regulations & Safety
United Airlines Wingtip Collision at SFO Spurs Safety Review
Second ground collision at San Francisco Airport in 13 months exposes staffing, training, and technology gaps in aviation ground operations.
On May 6, 2025, two United Airlines Boeing 777-300ER aircraft clipped wings during routine pushback procedures at San Francisco International Airport (SFO), marking the second such incident at the airport in just over a year. While no injuries were reported, the collision has reignited concerns about systemic safety failures in ramp operations at major U.S. airports.
With over 500 passengers affected and millions of dollars in damage, the incident underscores the growing risks associated with ground handling in high-traffic aviation hubs. It also highlights the urgent need for improved staffing, better training, and adoption of advanced safety technologies to mitigate future incidents.
As the Federal Aviation Administration (FAA) begins its investigation, industry experts and regulators are examining what went wrong, and what it means for the future of aviation safety, not just in the U.S., but globally.
According to FAA reports, United Airlines Flight 863 was scheduled to depart for Sydney, while Flight 877 was bound for Hong Kong. The incident occurred at 12:35 a.m. local time in a ramp area not actively managed by air traffic control. During pushback from Gate G98, Flight 863’s right wingtip struck the left wingtip of the stationary Flight 877.
Preliminary data indicates that the tug operator for Flight 863 had received clearance from United’s ramp control just minutes before the collision. Ground radio logs captured a warning from a controller noting tight clearance: “You’re pushing pretty deep here, confirm your wing walkers have visual on 877.”
The collision was confirmed visually by ground staff 23 seconds after the aircraft’s wingtip proximity alert system was triggered. The FAA is now investigating whether inadequate wing walker staffing contributed to the failure in spatial awareness.
“We’re constantly juggling flights with skeleton crews. Last month, I had three trainees monitoring four pushbacks simultaneously, that’s how mistakes happen,” United Airlines Ramp Supervisor Both aircraft involved were Boeing 777-300ERs, each with a wingspan of over 212 feet. Flight 863 sustained a 14-inch dent on the right winglet, while Flight 877’s left wingtip suffered a 9-inch composite fracture. Fortunately, no fuel leaks or hydraulic issues were detected.
Boeing has estimated that repairs will exceed $2.1 million per aircraft due to the need to replace carbon-fiber-reinforced components. The aircraft have been grounded pending full structural inspections and repairs. While the damage was localized, the financial and operational fallout is significant. United Airlines has already begun rebooking affected passengers and temporarily reduced international departures from SFO by 11% as a precautionary measure.
This is not the first time SFO has been the site of a ground collision. In April 2024, another United 777 experienced a similar wingtip contact during nighttime pushback. Other notable incidents include a cargo loader collision with a Delta A330 in July 2023 and a taxiway incursion involving a Lufthansa A380 in November 2022.
FAA data reveals that SFO’s ramp areas averaged 1.2 incidents per 10,000 aircraft movements in 2024, three times the national average for major airports. These statistics point to a broader concern about the safety of ground operations at high-volume hubs.
Globally, the Flight Safety Foundation reported 189 ground collisions in 2023, a 14% year-over-year increase. The organization identified inadequate staffing, communication failures, and fatigue as the leading causes.
The aviation industry continues to struggle with workforce shortages, especially in ground handling roles. Ramp worker turnover rates reached 27% in Q1 2024, up from 19% pre-pandemic. At the same time, training hours for new hires have decreased by 23% since 2019.
Increased reliance on overtime and compressed training schedules have created an environment ripe for errors. Many ramp workers are tasked with overseeing multiple aircraft simultaneously, often during nighttime operations when visibility is compromised.
These conditions not only increase the risk of incidents but also place undue stress on employees, further exacerbating turnover and fatigue-related mistakes.
Despite advancements in aviation technology, ground operations remain heavily reliant on manual processes. Only 12% of U.S. airports currently use LiDAR-based aircraft proximity alert systems. Most ground crews still rely on handheld radios without GPS integration. Although Boeing introduced its Obstacle Warning System (OWS) in 2022, it remains an optional feature due to its $287,000 per-unit cost. The National Transportation Safety Board (NTSB) has called for mandatory implementation of such systems, citing a 71% reduction in incidents at airports that have adopted them.
Without wider adoption of automated safety systems, ramp areas will continue to be vulnerable to human error, especially during high-traffic or low-visibility conditions.
In response to the SFO collision, the FAA announced a 30-day safety audit of ramp procedures at all Category X airports. The agency is also proposing new staffing standards, including minimum wing walker-to-aircraft ratios during pushback operations.
To encourage technological upgrades, the FAA will offer a 15% tax credit for airports that install ASTM F3423-22 compliant sensor systems. FAA Administrator Mike Whitaker emphasized that while air travel remains safe, “preventable ground incidents are unacceptable.”
These measures reflect a growing consensus that ground safety needs the same level of regulatory scrutiny as in-flight operations.
United Airlines has accelerated its Smart Ramp initiative, which includes real-time 3D mapping, biometric crew tracking, and autonomous pushback tugs. Delta and American Airlines are also investing heavily in AI and machine learning technologies to predict and prevent ground collisions.
Globally, regulators are taking notice. The International Civil Aviation Organization (ICAO) has proposed new training requirements for ramp crews, while the European Union Aviation Safety Agency (EASA) is funding research into ground automation technologies.
Manufacturers like Airbus and Boeing are under pressure to standardize safety features across their fleets. EASA recently delayed delivery approvals of Boeing 787s lacking factory-installed proximity sensors, signaling a shift toward stricter compliance standards. The wingtip collision at SFO serves as a stark reminder that aviation safety extends beyond the skies. As passenger volumes surge and airport operations grow more complex, ensuring safety on the ground is becoming just as critical as in-flight security.
To move forward, the industry must embrace a multi-pronged strategy: invest in technology, improve workforce conditions, and harmonize global safety standards. These steps will not only prevent future incidents but also restore public confidence in the safety of air travel.
What caused the collision at SFO? Were there any injuries? How much damage was caused? What is being done to prevent future incidents? Sources: CNN, Flight Safety Foundation, FAA, NTSB
Wingtip Collision at SFO: A Wake-Up Call for Ground Safety in Aviation
Incident Breakdown: What Happened at SFO?
Timeline and Operational Context
Damage Assessment and Aircraft Impact
Systemic Challenges in Ground Handling
Recurring Incidents at SFO and Beyond
Labor Shortages and Training Gaps
Technology Adoption: A Lagging Front
Regulatory and Industry Response
FAA’s Immediate Actions
Airline Initiatives and Industry Trends
Conclusion: Toward a Safer Ground Environment
FAQ
The collision occurred during pushback in a ramp area not overseen by air traffic control. Inadequate staffing and procedural lapses are suspected contributors.
No injuries were reported. All passengers deplaned safely and were rebooked on other flights.
Each aircraft sustained over $2 million in damage, primarily to wingtip components made from carbon fiber.
The FAA is conducting safety audits and proposing new staffing and technology standards. Airlines are also investing in automation and AI tools.
Photo Credit: SanFranciscoChronicles
Regulations & Safety
Stolen Cessna 172 Crashes into Hangar at Van Nuys Airport
A stolen Cessna 172 crashed into a hangar at Van Nuys Airport. Suspect arrested; FAA and FBI investigate security breach at busy general aviation airport.
This article summarizes reporting by NBC Los Angeles and Jonathan Lloyd.
A security breach at Van Nuys Airports (VNY) early Thursday morning resulted in the theft and subsequent crash of a single-engine aircraft. According to reporting by NBC Los Angeles, a suspect broke into a flight school facility and attempted to commandeer a Cessna 172 before crashing the plane into a nearby hangar building. Authorities have confirmed that the aircraft never successfully became airborne.
Law enforcement officials, including the Los Angeles Airport Police (LAXPD) and the FBI, responded immediately to the scene. The suspect was taken into custody without incident, and no injuries were reported on the ground or in the aircraft. The incident has prompted a federal investigation into the security protocols at one of the world’s busiest general aviation airports.
The incident began in the pre-dawn hours of December 18, 2025. According to a timeline compiled from reports by NBC4 and KTLA, the suspect trespassed onto the airport grounds around 4:00 AM. The individual targeted a flight training facility located near the 7900 block of Balboa Boulevard, an area densely populated with Commercial-Aircraft academies and hangars.
After gaining access to the flight school, the suspect boarded a white single-engine Cessna 172. Around 5:00 AM, the suspect attempted to operate the aircraft. NBC Los Angeles reports that the plane was stolen directly from the flight school’s ramp.
“A small plane crashed in a building at Van Nuys Airport after it was stolen from a flight school, officials tell NBC4 Investigates.”
— NBC Los Angeles
While the suspect managed to start the engine and begin taxiing, they lost control of the aircraft before reaching a runway. The plane surged forward and impacted a hangar nose-first. Aerial video footage broadcast by KTLA showed the aircraft’s nose embedded in the metal siding of the structure, leaving a distinct hole in the exterior wall. The propeller and nose cone sustained significant damage, rendering the aircraft inoperable.
Following the crash, LAXPD officers arrested the suspect at the scene. CBS Los Angeles and other local outlets have identified the individual as 37-year-old Ceffareno Michael Logan. He was booked on suspicion of burglary and theft of an aircraft. According to verified reports from Patch and NTD News, bail for Logan has been set at $150,000. As of the latest updates, authorities have not disclosed a motive for the theft, nor have they confirmed whether the suspect possessed any prior flight training or a pilot’s license. The swift arrival of law enforcement prevented any further attempts to move the aircraft or flee the scene.
The investigation has expanded beyond local police to include federal agencies. Both the Federal Bureau of Investigation (FBI) and the Federal Aviation Administration (FAA) are on-site to assist LAXPD. Their inquiry will likely focus on how the suspect breached the perimeter and accessed the aircraft keys or ignition system.
Crews were observed later in the morning extracting the damaged Cessna from the hangar wall and towing it back to the flight academy’s facility. Despite the dramatic nature of the event, airport operations at Van Nuys were not significantly disrupted, as the crash was contained within the flight school’s specific ramp area.
While commercial airports operate under the strict passenger screening protocols of the TSA, general aviation (GA) airports like Van Nuys face different security challenges. VNY is a massive facility with multiple access points for Private-Jets businesses, hangars, and flight schools. This incident highlights the vulnerability of “insider” areas where aircraft are parked.
Although rare, the theft of aircraft is a known risk in the aviation industry. In 2018, a ground service agent stole a Q400 turboprop from Seattle-Tacoma International Airport, a tragedy that ended in a fatal crash. Fortunately, in this instance at Van Nuys, the suspect failed to achieve flight, preventing a potentially catastrophic outcome over the densely populated San Fernando Valley. We anticipate this event will trigger a review of after-hours key storage and perimeter security standards for flight schools operating at VNY.
Stolen Cessna 172 Crashes into Hangar at Van Nuys Airport
Timeline of the Theft and Crash
The Break-in and Attempted Taxi
Suspect and Legal Proceedings
Investigation and Aftermath
AirPro News Analysis: General Aviation Security
Sources
Photo Credit: KTLA5
Regulations & Safety
US Government Admits Liability in 2025 Washington DC Mid-Air Collision
The U.S. government admits fault in the 2025 mid-air collision near Ronald Reagan Washington National Airport that killed 67, citing FAA and Army errors.
This article summarizes reporting by AP News.
In a significant legal development following the deadliest United States aviation accident since 2001, the U.S. government has formally admitted liability for the mid-air collision that claimed 67 lives earlier this year. According to court filings submitted in December 2025, the Department of Justice acknowledged that negligence by both Federal Aviation Administration (FAA) air traffic controllers and U.S. Army pilots caused the tragedy.
The crash, which occurred on January 29, 2025, involved American Eagle Flight 5342 and a U.S. Army Black Hawk helicopter operating near Ronald Reagan Washington National Airport (DCA). As reported by AP News, the government’s admission comes in response to a lawsuit filed by the family of a victim, signaling a potential shift in how the remaining legal battles regarding the disaster will proceed.
The lawsuit, filed by the family of passenger Casey Crafton, alleges that failures in communication and protocol led directly to the catastrophe. In a move that legal experts describe as unusually swift for complex aviation litigation, the government did not contest its role in the accident.
In the filing, the government stated that it:
“owed a duty of care to plaintiffs, which it breached.”
, U.S. Department of Justice filing, via AP News
By admitting liability, the government effectively removes the need for a trial to determine fault regarding its own agents (the FAA and the Army). The legal focus will likely shift toward determining the amount of damages owed to the families of the 64 people on the regional jet and the three crew members on the helicopter.
The collision occurred at night while the American Eagle CRJ700, operated by PSA Airlines, was on approach to DCA from Wichita, Kansas. The Black Hawk helicopter was conducting a training mission involving night vision goggles. Investigations cited by AP News and preliminary NTSB data highlight two primary causes for the disaster: air traffic control errors and pilot deviations. According to the reports, the FAA controller at DCA utilized “visual separation” procedures, asking the helicopter pilots if they had the incoming jet in sight. Once the pilots confirmed they did, the controller transferred the responsibility for maintaining safe distance to the helicopter crew. Following the incident, the FAA has reportedly restricted the use of visual separation for helicopters operating in this congested airspace.
The government’s admission also encompasses errors made by the Army flight crew. Investigators found that the helicopter was flying significantly higher than permitted for its specific route. While the limit for “Route 4” was 200 feet, the Black Hawk was operating between 278 and 300 feet, approximately 78 feet above the ceiling for that corridor.
Furthermore, technical discrepancies were noted in the helicopter’s equipment. The investigation revealed that the barometric altimeter may have displayed an altitude 80 to 100 feet lower than the aircraft’s actual position, potentially misleading the pilots. The use of night vision goggles was also cited as a factor that may have limited the crew’s peripheral vision and depth perception.
The speed at which the U.S. government admitted liability, less than a year after the incident, is notable. In many aviation disasters involving state actors, litigation can drag on for years over jurisdictional and immunity claims. We assess that this early admission is likely a strategic decision to limit the scope of discovery. By conceding fault now, the government may prevent a prolonged public trial that would expose granular, potentially sensitive details regarding military training operations and air traffic control systemic vulnerabilities in the nation’s capital.
While the government has accepted its share of the blame, the legal battle continues for the private carriers involved. American Airlines and its regional subsidiary, PSA Airlines, are also named defendants in the lawsuit. Both airlines have filed motions to dismiss the complaints against them, arguing that the sole responsibility lies with the government entities that controlled the airspace and the military aircraft.
Attorneys for the victims’ families, however, argue that the airlines failed to mitigate known risks associated with flying into the highly congested airspace around Washington, D.C. The outcome of these motions will determine whether the airlines must also pay damages or if the U.S. taxpayers will bear the full financial burden of the settlements.
When is the final NTSB report expected? What safety changes have been made since the crash? How many people died in the accident?
US Government Admits Liability in Fatal Collision Between American Eagle Jet and Army Helicopter
Government Concedes Negligence in Court Filing
Operational Failures Behind the Crash
FAA Controller Errors
Army Pilot Deviations
AirPro News Analysis
Ongoing Legal Disputes with Airlines
Frequently Asked Questions
The National Transportation Safety Board is expected to release its final report on the probable cause of the accident in early 2026.
The FAA has permanently closed the specific helicopter route (Route 4) involved in the crash. Additionally, regulators have prohibited the simultaneous use of certain runways at DCA during urgent helicopter missions and restricted visual separation procedures for helicopters.
The crash resulted in 67 total fatalities: 60 passengers and 4 crew members on the regional jet, and 3 crew members on the Army helicopter.
Sources
Photo Credit: NBC News
Regulations & Safety
Why Proper Maintenance of Aircraft Wheel Bearings Is Critical for Safety
Airbus technical data shows aircraft wheel bearing failures result mainly from maintenance errors. Proper torque, cleaning, and lubrication are essential for safety.
This article is based on technical guidance and safety publications from Airbus and additional industry safety reports.
Aircraft wheel bearings are among the most stressed components in aviation. Despite supporting loads of up to 500 tons and enduring temperature shifts from sub-zero cruising altitudes to the intense heat of braking, they remain largely hidden from view. According to a technical safety publication by Airbus, the failure of these components is rarely due to design flaws but is almost exclusively the result of improper maintenance.
At AirPro News, we have reviewed the latest guidance from Airbus’s “Safety First” initiative, alongside broader industry data, to understand why these small components continue to pose significant risks to flight safety. The consensus across manufacturers and regulators is clear: strict adherence to maintenance protocols is the only barrier against catastrophic failure.
The primary cause of bearing failure, as identified by Airbus and industry data, is maintenance error. Specifically, the issues revolve around incorrect torque application, contamination, and inadequate lubrication. Aircraft use “tapered roller bearings” designed to handle both the weight of the aircraft (radial loads) and side-to-side movement (axial loads). When these bearings are mistreated, the consequences are severe.
One of the most critical and frequently misunderstood aspects of wheel installation is the torque procedure. According to Airbus technical guidelines, a specific “double-torque” method is required to ensure the bearings are seated correctly without being overtightened.
The process generally involves three distinct steps:
The risk lies in the details. If a technician skips rotating the wheel during the initial torque application, the rollers may not align, leading to a false torque reading. This can result in loose bearings that vibrate and wear prematurely, or tight bearings that overheat and seize.
The failure of a wheel bearing is not merely a maintenance inconvenience; it is a direct threat to the structural integrity of the aircraft. When a bearing seizes, it can generate enough friction to weld components together or shear axles, leading to wheel separation.
In one notable case study highlighted by Airbus, an A330 aircraft lost a wheel during takeoff. The investigation revealed that a seized bearing destroyed the axle nut, allowing the wheel to eject from the landing gear. This is not an isolated event. Data from the Transportation Safety Board of Canada (TSB) underscores the prevalence of this issue. “A study revealed 67 occurrences of nosewheel bearing failures on A319/A320/A321 aircraft worldwide between 1989 and 2004.”
— TSB Canada Data
While the Airbus “Safety First” article focuses on their fleet, the physics of bearing failure applies universally. Reports from the UK Air Accidents Investigation Branch (AAIB) detail an incident involving a Boeing 737-800 where a seized bearing generated sufficient heat to compromise the chrome plating and base metal of the axle, causing it to fracture.
Similarly, an investigation into an Embraer EMB-145 (registration G-EMBP) found that moisture contamination due to improper seal installation led to severe overheating and subsequent axle failure. These incidents confirm that regardless of the airframe manufacturer, the root causes, contamination and torque errors, remain consistent.
To mitigate these risks, manufacturers and technical organizations like Timken have established “gold standard” maintenance manuals. The following practices are considered non-negotiable for airworthiness:
The Human Factor in Maintenance
While the technical steps are well-documented, we believe the persistence of these failures points to a human factors challenge. Wheel bearings are “hidden” components; unlike a tire that shows visible tread wear, a bearing often looks pristine until the moment it fails catastrophically. This lack of visual feedback places an immense burden on the maintenance process itself.
In high-pressure line maintenance environments, the requirement to rotate a wheel while torquing it, a process that relies on “feel” and patience, can be a trap for technicians rushing to clear an aircraft for departure. The data suggests that safety in this domain relies less on new technology and more on a disciplined adherence to the basics: cleaning, inspecting, and respecting the torque procedure.
Regulators continue to monitor these risks closely. The FAA has previously issued Airworthiness Directives, such as AD 2012-10-09 for Cessna 560XL aircraft, following reports of brake failure linked to loose bearing components. Furthermore, the FAA Safety Team (FAASTeam) frequently issues alerts reminding operators that “grease is not just grease,” warning that using unapproved substitutes constitutes a violation of FAR Part 43.
Whether operating a General Aviation aircraft or a commercial airliner, the message from the industry is uniform: take care of the wheel bearings, and they will carry the load.
The Hidden Danger in the Gear: Why Wheel Bearing Maintenance Cannot Be Rushed
The Mechanics of Failure
The “Double-Torque” Procedure
Real-World Consequences
Airbus and TSB Canada Data
Cross-Fleet Vulnerabilities
Industry Best Practices
AirPro News Analysis
Regulatory Context
Sources
Photo Credit: Airbus
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