Incident Overview
A large transport aircraft, subsequently identified as a DC-10, was involved in a rejected takeoff incident at an unspecified airport. During the takeoff roll, at a speed of 166 knots (the calculated V1 speed), the slat disagree illumination and takeoff warning horn activated. The flight crew initiated a rejected takeoff, but the aircraft continued to accelerate, reaching a ground speed of 178 knots before deceleration began.
Deceleration and Runway Excursion
The deceleration proceeded normally until the aircraft slowed to 130 knots, at which point an unexpected rapid decay in deceleration occurred. The aircraft departed the end of the runway at 95 knots. After leaving the paved surface, the nose landing gear collapsed, and the airplane came to rest approximately 1,100 feet beyond the runway end.
Brake System Failure
Post-accident examination revealed that eight of the ten brake sets had failed. The brakes exhibited excessive wear consistent with the energy demands of a rejected takeoff. Subsequent testing showed that worn brakes on this type of aircraft have a significantly higher wear rate during a rejected takeoff compared to new brakes. The Federal Aviation Administration does not require worn brake testing as part of certification. Additionally, the manufacturer did not incorporate brake wear data from rejected takeoff certification tests—which were conducted with new brakes—to establish more conservative brake wear replacement limits.
Evacuation and Aircraft Damage
All 254 occupants successfully evacuated the aircraft. Eight individuals sustained injuries, two of them serious. The aircraft itself sustained damage that rendered it beyond economical repair.
Official Findings and Probable Cause
The official investigation identified multiple contributing factors. A false indication from the wing slat system triggered the rejected takeoff. During the abort, the aircraft exceeded V1. The brake system was inadequate: the brakes were worn and subsequently failed totally. The manufacturer was cited for providing an inadequate component and for an inadequate substantiation process. The FAA was cited for inadequate certification and approval of the aircraft. Other factors included soft terrain beyond the runway and an approach light/navaid object that the aircraft struck.
The probable cause, as determined by the investigation, encompasses a false slat indication leading to a rejected takeoff, combined with inadequate brake performance attributable to worn brakes, insufficient manufacturer substantiation, and inadequate FAA certification/approval.