Engineered Materials Arresting Systems Prevent Runway Overrun Injuries

Aviation Safety Systems in Action: The Critical Role of Engineered Materials Arresting Systems in Preventing Catastrophic Runway Overruns

The recent incident at Roanoke-Blacksburg Regional Airport, where CommuteAir Flight 4339 overran the runway during heavy rain but was safely stopped by an Engineered Materials Arresting System (EMAS), underscores the essential role of advanced safety technologies in aviation. No injuries were reported among the 53 people aboard the United Express flight, highlighting how robust safety measures can prevent catastrophe even under adverse conditions. This event, involving a routine flight from Washington Dulles International Airport, showcased the effectiveness of EMAS, especially significant as the system had been upgraded in 2024 at a cost of $12 million.

Runway excursions remain a leading cause of aviation accidents globally. The Roanoke incident not only illustrates the persistent nature of this risk but also demonstrates the tangible benefits of investing in modern safety infrastructure. This article explores the specifics of the Roanoke case, the technology behind EMAS, broader runway safety trends, and the industry’s ongoing efforts to reduce the frequency and severity of runway excursions.

By examining expert insights, official data, and recent developments, we aim to provide a factual, balanced perspective on how safety systems like EMAS are shaping the future of aviation safety.

The Roanoke Airport Incident: A Case Study in Safety System Performance

On September 24, 2025, CommuteAir Flight 4339, operating as United Express, landed at Roanoke-Blacksburg Regional Airport amid heavy rain. The Embraer 145 jet, carrying 50 passengers and three crew, experienced a “long landing,” touching down later than intended and unable to stop on the wet runway. According to passengers, the landing was hard and late, with one describing the brakes coming on just as the plane neared the cross runway.

The aircraft overran the runway, entering the EMAS bed installed at the runway’s end. This system, upgraded in 2024, performed as designed: the jet’s wheels sank into the crushable material, decelerating the aircraft safely. All passengers and crew were evacuated without injury, and local emergency services responded promptly. The airport temporarily closed but resumed partial operations within hours, with full service restored by morning.

The Roanoke runway is approximately 1,000 feet shorter than many commercial airports, presenting unique operational challenges. Heavy rain and limited visibility further complicated the situation, demonstrating how even routine flights can encounter unexpected hazards. The incident’s resolution highlights the importance of layered safety measures, from pilot training to ground-based technologies like EMAS.

“It suddenly went down and it had a very hard but very late landing. The brakes came on just about the time they were going to hit the cross runway.” — Steve Harrison, passenger on Flight 4339

Understanding Engineered Materials Arresting Systems (EMAS)

EMAS is a ground-based safety solution designed to stop aircraft that overrun the runway. It consists of a bed of engineered, crushable material, such as cellular concrete or foamed silica, installed at the runway’s end. When an aircraft enters the EMAS, its wheels sink into the material, slowing the plane in a controlled manner and preventing more serious outcomes.

The Federal Aviation Administration (FAA) began supporting EMAS development in the 1990s to address airports where traditional safety areas could not be constructed due to space constraints. The first EMAS was installed at JFK International Airport in 1996. Today, over 120 EMAS systems are in place at more than 70 airports across the United States.

Two main EMAS technologies are currently used: EMASMAX (cellular concrete blocks) and greenEMAS (foamed silica from recycled glass). Both meet FAA standards and have a perfect safety record, since 1996, EMAS has safely stopped 25 aircraft overruns, protecting nearly 500 passengers and crew with no fatalities.

“EMAS functions like a truck emergency exit ramp or a foam pit for a gymnast, letting the plane slow down but also not be destroyed.” — Prof. Ella Atkins, Virginia Tech Aerospace Engineering

Economic and Operational Considerations

Installing EMAS is a significant investment. The Roanoke upgrade, for example, cost $12 million, funded by federal, state, and local sources, including passenger facility charges. However, the cost is justified when compared to the potential financial and human losses from a serious runway excursion.

Runway excursions can lead to aircraft damage or loss, infrastructure repairs, legal claims, and prolonged airport closures. By preventing such incidents, EMAS not only saves lives but also protects airports and airlines from substantial economic repercussions.

Insurance industry data and risk assessments increasingly recognize the value of EMAS, with some insurers factoring its presence into premium calculations. The system’s track record and growing adoption reflect a broader industry commitment to proactive risk management.

Runway Excursions: A Persistent Safety Challenge

Runway excursions, when an aircraft veers off or overruns the runway, are among the most common and dangerous types of aviation accidents. According to the International Civil Aviation Organization (ICAO), they account for the vast majority of runway-related incidents worldwide.

In 2024, runway excursions were the second most frequent accident type globally, with 20 airliner accidents reported (up from 7 in 2023). These incidents affected both jet and turboprop aircraft, with a majority occurring during landing. Certain regions, such as Africa, have seen higher rates of such accidents, underscoring the importance of context-specific safety strategies.

Business and corporate aviation is particularly affected. Between 2019 and 2024, 76 runway excursion accidents were recorded in corporate jet operations, representing 41% of all such accidents in this sector and resulting in several fatalities. Contributing factors include unstable approaches, adverse weather, and operational errors.

“Runway excursions cause serious and sometimes fatal injuries, destroy aircraft, lead to costly litigation, and negatively impact operator reputation.” — National Business Aviation Association

Weather and Human Factors

Weather is a major contributor to runway excursions. Heavy rain, poor visibility, and strong crosswinds increase the risk, as seen in the Roanoke incident and others, such as the Norwegian Boeing 737-800 overrun in Molde during a severe storm in December 2024.

Human factors also play a role. Studies indicate that nearly half of serious runway excursions are linked to unstabilized approaches, where pilots continue to land despite not meeting approach criteria. Other factors include non-adherence to procedures, wildlife on runways, and loss of situational awareness.

Addressing these risks requires a combination of technological solutions, improved training, and robust operational procedures. EMAS is one part of a broader runway safety strategy that includes regular runway inspections, enhanced weather monitoring, and data-driven decision-making.

Trends in Aviation Safety and the Impact of EMAS

Aviation safety has improved dramatically over the past decade. According to the International Air Transport Association, the global accident rate has declined steadily, with 2023 marking one of the safest years on record. While 2024 saw a slight increase in accident numbers, the overall trend remains positive.

EMAS has played a key role in this progress. In September 2025 alone, three aircraft were safely stopped by EMAS beds at different U.S. Airports, including Roanoke, Chicago Executive, and Boca Raton. Each incident ended without serious injury, demonstrating the system’s effectiveness across various aircraft types and operational contexts.

The FAA and industry leaders continue to advocate for expanded EMAS deployment, not only in the U.S. but internationally. The system’s proven success is leading to its adoption in other countries, supported by technology transfer and regulatory guidance from U.S. authorities.

“These two systems did exactly what they’re designed to do, stop aircraft safely when they go off the runway.” — FAA Administrator Bryan Bedford

Expert and Regulatory Perspectives

Experts emphasize that while EMAS is highly effective, it is intended as a last line of defense. Pilots are trained to avoid relying on it, instead aiming for stabilized approaches and safe landings under all conditions. However, when all else fails, EMAS provides a critical safety net.

Regulatory agencies, such as the FAA and National Transportation Safety Board (NTSB), continue to monitor runway safety data and update standards as needed. The NTSB has called for more proactive responses to identified risks, citing past failures to act on recurring Safety alerts as a lesson for the industry.

International organizations like ICAO and the Flight Safety Foundation provide toolkits and best practices to help airports and Airlines address runway excursion risks through a combination of infrastructure, technology, and operational improvements.

Conclusion

The Roanoke-Blacksburg Regional Airport incident is a compelling example of how modern safety systems, especially EMAS, can prevent disaster in challenging conditions. The absence of injuries or fatalities, despite a runway overrun in heavy rain, validates the significant investments made in aviation safety infrastructure. The incident also highlights the importance of continuous improvement and adaptation, as new risks, such as those posed by changing weather patterns, emerge.

Looking ahead, the aviation industry must maintain its commitment to safety through ongoing investment, innovation, and international collaboration. EMAS and similar technologies will remain vital components of runway safety, but their effectiveness depends on integration with broader strategies involving training, regulation, and data-driven risk management. As air travel continues to grow, these lessons will be essential in ensuring that aviation remains one of the safest modes of transportation.

FAQ

What is EMAS and how does it work?
EMAS (Engineered Materials Arresting System) is a bed of crushable material installed at the end of airport runways. If an aircraft overruns the runway, its wheels sink into the EMAS, slowing and stopping the plane safely.

How many lives has EMAS saved?
Since its first installation in 1996, EMAS has safely stopped 25 overrunning aircraft in the U.S., protecting nearly 500 passengers and crew with no reported fatalities.

Why are runway excursions still a concern?
Runway excursions remain common due to factors like adverse weather, operational errors, and infrastructure limitations. While safety has improved, these incidents are difficult to eliminate entirely, making systems like EMAS essential.

Who pays for EMAS installations?
Funding for EMAS typically comes from a mix of federal aviation grants, state and local contributions, and passenger facility charges.

Is EMAS used outside the United States?
While EMAS is most widely used in the U.S., its adoption is growing internationally, with the FAA supporting foreign airport installations.

Sources

• AP News