UPS and FedEx Ground MD-11 Fleets After Louisville Crash

Titans of the Sky Grounded: UPS and FedEx Halt MD-11 Operations After Tragedy

In a significant move reverberating through the global logistics industry, United Parcel Service (UPS) and FedEx have grounded their entire fleets of McDonnell Douglas MD-11 aircraft. This decision, described by both companies as a measure taken “out of an abundance of caution,” follows a catastrophic and deadly crash of a UPS MD-11 at its global air hub in Louisville, Kentucky. The grounding was initiated at the recommendation of Boeing, the successor to McDonnell Douglas, underscoring the serious nature of the concerns that have arisen since the incident.

The logistics world relies heavily on the seamless operation of its air cargo fleets, and the MD-11, a venerable workhorse of the skies, has been a key component of both UPS and FedEx’s long-haul operations for decades. While representing a relatively small percentage of their total fleets, about 9% for UPS and 4% for FedEx, the grounding of these powerful tri-jet aircraft creates immediate operational challenges. Both companies have activated contingency plans to mitigate service disruptions, but the sudden removal of a specialized, heavy-lift aircraft from service is a complex problem to solve. The incident and subsequent grounding place a sharp focus on aviation safety, aircraft manufacturing, and the intricate processes that keep global supply chains moving.

The investigation, now in the hands of the National Transportation Safety Board (NTSB), is in its early stages, but the initial findings have already painted a grim picture of the flight’s final moments. As the industry holds its breath, questions surrounding the MD-11’s service history, the specifics of the crash, and the manufacturer’s recommendation to ground the fleet will be at the forefront of a complex and far-reaching inquiry. The decisions made in the coming weeks will not only affect the future of this specific aircraft model but will also have lasting implications for cargo aviation safety protocols worldwide.

The Crash of UPS Flight 2976

On the evening of Tuesday, November 4, 2025, UPS Flight 2976, an MD-11 freighter registered as N259UP, was preparing for a long-haul journey from Louisville Muhammad Ali International Airport (SDF) to Honolulu (HNL). Shortly after 5:15 PM EST, during its takeoff roll from the UPS Worldport hub, a catastrophic failure occurred. The flight, crewed by three pilots, ended in tragedy, claiming the lives of all 14 people on board and in the vicinity of the crash. The aircraft barely lifted off the runway before crashing into nearby industrial buildings, resulting in a massive fireball and a devastating scene of destruction.

The NTSB’s on-site team of over 30 investigators, led by Board Member Todd Inman, has been meticulously piecing together the events of that evening. The recovery of the cockpit voice recorder (CVR) and flight data recorder (FDR) has provided crucial initial insights. Data from the CVR revealed that a bell began to sound in the cockpit just 37 seconds after the crew initiated takeoff thrust. This warning continued for 25 seconds as the pilots fought to control the crippled aircraft. Preliminary evidence points to the disintegration and detachment of the aircraft’s left engine (engine No. 1) during the takeoff sequence. Eyewitness accounts and initial findings suggest the left wing was engulfed in flames as the plane struggled for altitude.

According to aviation experts, the timing of the engine failure was critical. Jeff Guzzetti, a former federal crash investigator, suggested the audible alarm was likely an engine fire warning. He noted that the event probably occurred after the aircraft had passed its “decision speed”, the point during takeoff at which it is no longer safe to abort and attempt to stop on the remaining runway. This left the crew with no choice but to attempt to fly the severely damaged aircraft, a task that tragically proved impossible. The investigation will now delve deeper into the aircraft’s maintenance history, including a recent period of service in San Antonio from September to October 2025, to determine the root cause of the engine failure.

“It occurred at a point in the takeoff where they were likely past their decision speed to abort the takeoff. They were likely past their critical decision speed to remain on the runway and stop safely.” – Jeff Guzzetti, former federal crash investigator.

The MD-11: A Storied but Complicated History

The McDonnell Douglas MD-11, the world’s largest tri-jet, occupies a unique place in aviation history. Developed as a successor to the venerable DC-10, it first flew in 1990 and was produced until 2000, with Boeing overseeing the final years of production after its merger with McDonnell Douglas in 1997. While initially designed for passenger service, its operational economics led most airlines to phase it out in favor of more efficient twin-engine jets. However, its impressive payload capacity and range made it an ideal candidate for a second life as a cargo aircraft, where it has served faithfully for carriers like UPS, FedEx, and Western Global Airlines.

Despite its capabilities, the MD-11 has a safety record that has drawn scrutiny over the years. As of November 2025, the aircraft has been involved in 50 incidents, including 11 hull-loss accidents that have resulted in 257 fatalities. Several of these incidents have involved landing difficulties and in-flight emergencies. Notable accidents include FedEx Express Flight 14 in 1997, which crashed on landing at Newark, and FedEx Express Flight 80 in 2009, which suffered a similar fate at Narita, Japan, killing both pilots. The deadliest incident involved Swissair Flight 111 in 1998, a passenger MD-11 that crashed off Nova Scotia due to an in-flight fire, killing all 229 people on board.

The decision by Boeing to recommend the grounding of the remaining active MD-11s is a significant development. While both UPS and FedEx have stated they are acting on this recommendation, Boeing itself has not yet publicly detailed the specific reasons behind its advisory. This lack of information has led to speculation within the industry, but it strongly suggests that the initial findings from the Louisville crash may point to a potential systemic issue that could affect other aircraft in the fleet. The NTSB’s full investigation will be critical in determining whether the cause was a one-off maintenance error, a design flaw, or another issue that warrants such a drastic and immediate response from the manufacturer and operators.

Awaiting Answers and Navigating Disruption

The grounding of the MD-11 fleets by UPS and FedEx marks a pivotal moment of reflection and action for the air cargo industry. The immediate priority is the ongoing NTSB investigation, which will take months, if not years, to complete. A preliminary report is expected within about 30 days, but a final determination of the probable cause will require extensive analysis of the wreckage, flight recorders, maintenance records, and metallurgical testing. The findings will be crucial in shaping the future of the MD-11 and could influence safety and maintenance protocols for other aging freighter aircraft across the industry.

In the interim, the operational impact on the two logistics giants is a pressing concern. While the MD-11s are a minority of their total fleets, they are vital for high-capacity, long-distance routes. Both companies are now scrambling to adjust schedules, reroute shipments, and potentially bring other aircraft into service to cover the gaps. This disruption comes at a critical time for global supply chains, and while both UPS and FedEx have robust contingency plans, the sudden loss of a key aircraft type will undoubtedly test their resilience. The incident serves as a stark reminder of the immense responsibility that rests on the shoulders of air cargo carriers and the critical importance of uncompromising safety standards.

FAQ

Question: Why did UPS and FedEx ground their MD-11 planes?
Answer: Both companies grounded their MD-11 fleets “out of an abundance of caution” following a deadly crash of a UPS MD-11 in Louisville, Kentucky. The decision was made at the recommendation of the aircraft’s manufacturer, Boeing.

Question: What is the NTSB investigating in the Louisville crash?
Answer: The NTSB is conducting a full investigation. Preliminary findings suggest the aircraft’s left engine disintegrated and detached during takeoff. Investigators are analyzing the cockpit voice and flight data recorders and the aircraft’s maintenance history to determine the cause.

Question: How many MD-11s do UPS and FedEx operate?
Answer: The MD-11 aircraft make up approximately 9% of the UPS airline fleet and about 4% of the FedEx fleet.

Sources

• NPR