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The REAL story About the Crash that Killed Concorde! | Air France flight 4590

Mentour Pilot・2 minutes read

Numerous technical issues and a heavier-than-planned aircraft led to the tragic crash of Air France Flight 4590, caused by a single burst tire that ignited fuel tanks, ultimately resulting in the Concorde's retirement in 2003.

Insights

  • The Concorde's complex fuel system with 13 tanks, including a trim tank for center of gravity adjustments, played a crucial role in the Flight 4590 accident due to a fuel tank rupture and ignition, highlighting the importance of meticulous maintenance and safety protocols in aviation.
  • The catastrophic accident of Flight 4590 was primarily triggered by a single burst tire, leading to structural improvements and the eventual grounding of the Concorde fleet, emphasizing the critical impact of seemingly minor technical issues and the necessity for comprehensive training to handle unexpected emergencies in aviation operations.

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Recent questions

  • What caused the Concorde Flight 4590 crash?

    Tire burst led to fuel tank rupture and fire.

  • How many engines did the Concorde have?

    Four engines with afterburner capability.

  • What was the Concorde's maximum fuel load?

    95 tons, close to maximum structural weight.

  • How many passengers were on Concorde Flight 4590?

    100 passengers, 6 cabin crew, and 3 pilots.

  • What was the Concorde's wing design?

    Delta wing design requiring high speeds for lift.

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Summary

00:00

Tragic Concorde Flight 4590: A Fatal Error

  • Air France Flight 4590, a shorter flight from Paris to New York, was scheduled for 100 passengers, 6 cabin crew, and 3 pilots on the legendary Aerospace Bac Concorde.
  • The Concorde's delta wing design required high speeds and angles for lift during takeoff and landing, leading to tire bursts and structural issues over its 30-year history.
  • Following a tire burst incident in 1979, investigations focused on tire strength and hydraulic system protection, with minimal concern for fire risk from fuel leaks.
  • The Concorde's complex fuel system included 13 tanks, with the 13th acting as a trim tank for center of gravity adjustments, crucial for takeoff.
  • The Concorde's four Olympus twin-spool turbojet engines featured afterburner capability, providing extra thrust during takeoff.
  • On the day of departure, technical issues and passenger discrepancies caused delays and adjustments to the flight plan, resulting in a heavier aircraft than planned.
  • The experienced flight crew, including a captain, first officer, and flight engineer, prepared for departure with a final fuel load of 95 tons, close to the maximum structural weight.
  • During taxi and pre-departure checks, a minor electrical control system issue with the rudder was noted but deemed non-impactful for the flight.
  • As the Concorde taxied for takeoff, a fuel transfer was completed to adjust the center of gravity, while a DC-10 incident on the same runway went unnoticed.
  • Despite a tailwind affecting the maximum takeoff weight, the Concorde was cleared for takeoff, with the crew unaware of the reduced weight limit due to the tailwind, leading to critical consequences during the flight.

14:58

Aircraft Engine Failure Leads to Fatal Crash

  • At 14:42:30, the captain advances the trust levels to off trust, causing the engines to roar with full thrust.
  • The aircraft accelerates down the runway, with the first officer calling out "100" followed by the flight engineer saying "four greens" indicating normal engine operation.
  • At 14:43:09, a slight yaw to the left is noted, possibly caused by a metal strip left by a previous aircraft.
  • Noise in the cockpit suggests an explosion of a tire on the left main gear, leading to a fuel tank rupture.
  • Pieces of the fuel tank found on the runway indicate an internal rupture, with fuel gushing out and igniting.
  • The aircraft veers left due to tire damage and aerodynamic drag from the fire, losing thrust on engines one and two.
  • The crew faces challenges with airspeed and engine failures, with engine one recovering slightly but engine two shutting down.
  • The aircraft struggles to climb due to engine damage, with engines three and four in contingency mode to compensate.
  • The crew receives warnings of flames trailing behind and struggles with retracting the landing gear.
  • The aircraft experiences uncommanded roll and pitch, leading to a crash into a hotel, resulting in fatalities.

31:05

Concorde Crash: Tire Explosion Investigation Findings

  • Investigators found that the brake temperatures were potentially higher on the left-hand side during the takeoff roll, but no extra drag was detected from the left wheel boogie until the aircraft crossed a metal strip, causing a tire explosion.
  • The missing spacer, a major lapse by Air France, did not impact the accident sequence, leading investigators to focus on Continental Airlines and their DC-10, which had a faulty metal strip that had been replaced twice within two months and was not manufactured correctly.
  • The pilots were untrained for the scenario of losing both engines on one side with a fuel leak and fire, leading to a takeoff commitment after running over the metal strip; rejecting takeoff would likely have resulted in a high-speed runway overrun and a gear collapse.
  • The investigation team concluded that the catastrophic accident was caused by a single burst tire, leading to the withdrawal of the Concorde's airworthiness certificate and the implementation of structural improvements, grounding the aircraft for over a year before its retirement in 2003 due to the 9/11 attacks and subsequent industry changes.
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