The aircraft, converted for cargo operations from a passenger model in 2004, had no prior recorded issues, making the sudden outbreak of fire particularly alarming.

The incident underscored critical safety vulnerabilities within the air cargo industry, leading to widespread scrutiny and discussions on improving safety protocols and regulations. The investigation involved a collaborative effort from various organizations, including representatives from Israel’s Ministry of Transport and the FBI, reflecting the incident’s complexity and significance in the aviation sector.

These findings raised questions about the adequacy of existing safety measures and the need for improved training for cargo pilots, as well as better oversight of operational practices in the industry. In the aftermath of the incident, multiple lessons emerged regarding aviation safety management, emphasizing the necessity for robust Safety Management Systems (SMS) tailored for cargo operations.

The NTSB recommended enhancements in emergency exit protocols and ongoing safety assessments, particularly for smaller cargo carriers, highlighting the importance of thorough incident analysis and regulatory compliance to mitigate risks in the future.

This incident not only highlighted pressing concerns regarding air cargo safety but also ignited a debate on regulatory reform, underscoring the need for alignment between cargo and passenger aviation safety standards. The ABX B767 cargo aircraft fire serves as a pivotal case study in understanding the complexities of aviation safety in cargo operations, stressing the urgency of maintaining rigorous safety protocols and fostering an industry-wide culture of proactive risk management to prevent similar occurrences.

On July 14, 2009, an ABX Air Boeing 767 cargo aircraft was involved in a serious fire incident shortly after takeoff, which prompted a comprehensive investigation by the National Transportation Safety Board (NTSB), the Federal Aviation Administration (FAA), and international agencies.

Reasons for the Fire

The fire incident involving the ABX Air Boeing 767-200 on June 28, 2008, was attributed to multiple factors related to both operational practices and aircraft design. Investigators from the National Transportation Safety Board (NTSB) identified deficiencies in oversight and safety measures that contributed to the event. The fire originated in the supernumerary section behind the cockpit, shortly after cargo loading and before the aircraft’s engines were started for taxiing

Design Flaws

A critical factor in the fire was the design of the supplemental oxygen system within the supernumerary compartment, which had been modified by Israeli Aircraft Industries (IAI) when converting the aircraft from passenger to cargo configuration. The modifications made during this conversion process failed to meet safety standards, leading to the malfunction that triggered the fire

Electrical and Operational Risks

Public speculation also pointed to potential electrical failures as a possible cause of the fire, including the combustion of a battery

Electrical systems are critical components of aircraft, and any malfunction can have serious implications. According to expert analysis, fires in aviation can vary significantly in scale and impact. Small, contained fires can typically be managed with onboard extinguishers, while larger, spreading fires pose a significant threat and can compromise pilot operation through smoke inhalation or damage to flight controls.

The NTSB’s inquiry focused on identifying the fire’s cause, which was linked to deficiencies in safety management practices, especially concerning the aircraft’s supplemental oxygen system and electrical risks.

Investigation

The investigation into the ABX B767 cargo aircraft fire on July 14, 2009, involved a thorough review of the circumstances leading to the incident and the underlying safety protocols in place. The National Transportation Safety Board (NTSB) conducted a detailed analysis that included site visits to key locations such as Alaska, Ohio, and Texas, chosen for their geographic diversity and high incidence of air cargo accidents.

Methodology

To identify the factors contributing to air cargo accidents, the NTSB reviewed data from 417 completed investigations, analyzing probable causes and contributing factors.

 Furthermore, they assessed accumulated risk by utilizing the Federal Aviation Administration’s (FAA) proposed flight risk assessment tool, focusing on 93 fatal cargo accidents within the review period.

This involved searching accident reports for specific risk factors, including pilot flight time and operational deficiencies. The investigation adhered to generally accepted government auditing standards, ensuring the findings were based on sufficient and appropriate evidence.

Findings

A critical aspect of the investigation highlighted the need for improvements in safety management within the air cargo industry. The NTSB criticized ABX’s in-house continuing airworthiness program for its failure to address persistent issues with the aircraft’s oxygen system, which had been unresolved for 18 months prior to the fire.

As a response, the NTSB recommended that the FAA modify its Airworthiness Directive (AD) process to consider broader design similarities in accessories identified as problematic.

The NTSB also called for enhanced safety measures, including better separation of oxygen and electrical lines, the installation of smoke detectors in supernumerary areas, and regular checks of passenger reading lights, which were found to pose a risk of sparking.

Expert Opinions

Experts in the field expressed varying views on the effectiveness of improved on-board technologies for enhancing safety. A panel of experts representing part 135 operators did not unanimously agree on the potential benefits of these technologies, with only one out of six indicating that such improvements were a top priority. The others cited concerns over the affordability of advanced safety systems relative to the aircraft’s value.

The investigation underscored the importance of identifying and analyzing hazards proactively, as emphasized by the International Civil Aviation Organization (ICAO), to prevent incidents before they escalate into accidents.

The National Academy of Engineering also noted that current initiatives in aviation safety management could be more effective, urging regulatory bodies to increase support for research in this area.

Through these findings, the investigation aimed to enhance the safety protocols in the air cargo industry and prevent similar incidents in the future.

By – Aeropeep Team

Categorized in:

Aircraft Engineering,

Last Update: April 11, 2025

Tagged in:

, , ,