What happened
On 23 June 2015, an Airbus A321-231, registration G-ZBAD, was being repositioned at Manchester Airport. Following a standard pushback from Stand 86R, the aircraft needed to be pulled forward onto the taxiway centerline due to the location of a perimeter fence. The ground operation involved two crew members: a tug driver and a headset operator responsible for communicating with the flight crew.
To improve visibility during the forward movement, the tug driver raised the cabin of the tug. The headset operator monitored this process, using hand signals to indicate when the cabin was clear and when to stop raising it. As the tug began to pull the aircraft, the headset operator noticed the raised cabin approaching the underside of the aircraft and attempted to alert the driver. However, the driver was looking away at the time.
After the aircraft had moved approximately 2 to 3 meters, the tug driver heard a noise and applied the brakes. The roof of the tug's cabin and its beacon light had struck the aircraft, resulting in a puncture to the underside of the fuselage just behind the radome. The impact also caused the towbar's shear pin to break. There were no injuries to the 193 passengers or the 7 crew members on board, and the passengers were able to disembark safely.
The investigation
Investigators examined the equipment and procedures used during the maneuver. While the towbar used during the incident was technically compatible with the aircraft type, it was significantly shorter than the 5,200 mm bars typically used for this aircraft at the airport. The towbar in use measured only 4,300 mm. The investigation also looked into the communication between the ground crew and the driver's line of sight during the movement.
Findings
- The tug's cabin had been raised by approximately 45-55 cm to assist the driver's visibility.
- The headset operator's attempt to signal the driver was unsuccessful because the driver was not looking toward the operator or the aircraft.
- The use of a shorter towbar contributed to the proximity of the tug cabin to the aircraft fuselage.
Safety action
- The 4,300 mm towbar has been removed from service by the handling agent.