The US Federal Aviation Administration (FAA) has issued an emergency order grounding all McDonnell Douglas MD-11 and MD-11F aircraft after the fatal crash of a UPS freighter in Louisville, Kentucky, which claimed fourteen lives. The directive, issued under the designation Emergency Airworthiness Directive 2025-23-51, took effect four days after UPS Flight 2976, operated by an MD-11F registered N259UP, crashed shortly after takeoff from Louisville Muhammad Ali International Airport (SDF). The accident killed all three crew members and eleven people on the ground.
The FAA stated that detailed structural inspections and all necessary corrective actions must be completed before any further flights, warning that the identified condition could compromise the aircraft’s ability to remain controllable and land safely. The two largest operators of the type, UPS and FedEx, had already grounded their fleets several days earlier after Boeing, which inherited the MD-11 program through its merger with McDonnell Douglas, recommended a temporary suspension of operations. UPS currently operates 26, and FedEx 28 MD-11 aircraft, representing roughly nine and four percent of their respective fleets. Both carriers said they are shifting long-haul operations to Boeing 767 and 777 freighters, though some shipment delays are expected. Western Global Airlines, the only other US operator, has already parked most of its aircraft.
The MD-11 first flew in 1990, with production ending in 2000. Today, the type serves almost exclusively as a cargo aircraft; around one hundred remain in active service worldwide, primarily with UPS and FedEx. Preliminary findings from the National Transportation Safety Board (NTSB) indicate that the left engine and its pylon separated during takeoff. Video footage shows the aircraft climbing briefly before rolling left and crashing into nearby buildings, igniting a major fire. Investigators have recovered the flight recorders, and early analysis indicates a continuous cockpit warning bell until impact. Special attention is being given to recent maintenance performed at the ST Engineering facility in Texas, where structural repairs were carried out several weeks before the accident.
The grounding of the MD-11 fleet comes at the busiest time of the year for global cargo operations, just ahead of the holiday season. Although UPS and FedEx say they can reroute shipments using other aircraft types, network disruptions are expected until inspections are completed and the FAA clears the MD-11 to return to service. The aircraft will remain grounded until all operators comply with FAA safety requirements, while the final NTSB report will determine whether additional measures will be required for the remainder of this aging but still active fleet.
