British Airways
British Airways Flight 5390 (1990)
Flight Information
- Flight: British Airways 5390 (BA5390)
- Date: June 10, 1990
- Aircraft: BAC One-Eleven 528FL
- Registration: G-BJRT
- Route: Birmingham (BHX) → Málaga (AGP)
- Occupants: 87 (81 passengers, 6 crew)
- Fatalities: 0
- Injuries: 7 (minor)
The Windscreen Blowout
On June 10, 1990, British Airways Flight 5390 was climbing out of Birmingham Airport bound for Málaga, Spain, with 87 people aboard. The BAC One-Eleven 528FL, registration G-BJRT, was a reliable workhorse aircraft that had been in service since 1971. Captain Tim Lancaster, 42, and First Officer Alastair Atchison, 39, were experienced pilots familiar with the aircraft type.
Just 13 minutes into the flight, while climbing through 17,300 feet over Oxfordshire, a catastrophic failure occurred that would test the limits of human courage and aviation training. The left windscreen of the cockpit suddenly blew out with explosive force, creating one of the most dramatic emergencies in aviation history.
What followed was an extraordinary display of airmanship, teamwork, and human determination that saved all 87 lives aboard and became a legendary tale of survival against impossible odds.
Timeline of Emergency
The Fatal Maintenance Error
Previous Night's Work
On the night of June 9-10, 1990, a maintenance technician at Birmingham Airport replaced the left windscreen of the BAC One-Eleven. This routine maintenance task, performed thousands of times across the aviation industry, would prove to have a fatal flaw in execution.
Critical Errors
- Wrong bolt specifications used for windscreen attachment
- A4 bolts used instead of required A4-80 high-strength bolts
- 90 bolts were 0.66mm too small in diameter
- Insufficient visual inspection after installation
- Lack of proper torque checking procedures
The Selection Error
The maintenance technician selected the replacement bolts by sight and feel rather than consulting the parts manual. The wrong bolts looked similar to the correct ones but lacked the necessary strength to withstand the differential pressure loads at altitude. This fundamental error would prove catastrophic.
The Explosive Decompression
Sudden Failure
At 17,300 feet, the differential pressure between the cabin and outside atmosphere was approximately 8.5 pounds per square inch. The undersized bolts finally failed under this load, causing the left windscreen to blow out instantaneously with explosive force.
Immediate Effects
- Captain Lancaster sucked out of aircraft to his waist
- Rapid decompression and temperature drop to -17°C
- Loud noise and severe windblast in cockpit
- Flight bag and other loose items blown out
- Autopilot disconnected due to control disruption
Human Chain of Survival
Flight attendant Nigel Ogden immediately grabbed Captain Lancaster's legs, preventing him from being completely ejected from the aircraft. Cabin crew member Susan Prince and passenger Atchison helped hold the captain while First Officer Atchison took control of the aircraft. This human chain literally saved the captain's life.
Heroic Airmanship
First Officer Takes Command
With Captain Lancaster incapacitated and hanging outside the aircraft, First Officer Alastair Atchison took immediate control. Despite the noise, freezing air, and debris flying around the cockpit, he maintained his composure and began executing emergency procedures.
Emergency Actions
- Immediately began emergency descent to safe altitude
- Declared Pan-Pan emergency to air traffic control
- Diverted to Southampton Airport (nearest suitable airfield)
- Managed aircraft systems despite extreme conditions
- Coordinated with cabin crew throughout emergency
Cabin Crew Heroics
The cabin crew's actions were nothing short of heroic. While holding onto Captain Lancaster in freezing, hurricane-force winds, they also managed to calm passengers, secure the cabin, and assist the First Officer. Their coordinated response was textbook crew resource management under the most extreme circumstances.
Investigation Findings
AAIB Investigation
The Air Accidents Investigation Branch (AAIB) conducted a thorough investigation that revealed the maintenance error was the primary cause. However, they also identified systemic issues in maintenance procedures and oversight.
Direct Causes
- Wrong bolt specification selected
- Inadequate bolt strength for pressure loads
- Poor lighting during maintenance work
- Lack of proper verification procedures
Contributing Factors
- Time pressure during maintenance shift
- Insufficient training on bolt identification
- Lack of mandatory reference to technical manuals
- Poor quality control procedures
Safety Improvements
The BA5390 incident led to significant improvements in aircraft maintenance procedures and quality control systems worldwide.
Maintenance Improvements
- Parts Identification: Mandatory use of technical manuals for part selection
- Quality Control: Enhanced inspection and verification procedures
- Training: Improved training on critical component maintenance
- Documentation: Better record-keeping and tracking systems
Regulatory Changes
- Maintenance Standards: Stricter certification requirements for technicians
- Supervision: Enhanced oversight of critical maintenance tasks
- Equipment: Better tools and lighting for maintenance work
- Procedures: Mandatory double-checking for safety-critical components
References & Further Reading
- 📄 AAIB Final Report (PDF)
Air Accidents Investigation Branch comprehensive investigation report
- 🌐 Wikipedia: British Airways Flight 5390
Detailed account with crew information and aftermath
Miracle of Teamwork
British Airways Flight 5390 demonstrated the extraordinary power of human courage, quick thinking, and teamwork under the most extreme circumstances. The heroic actions of the crew saved all 87 lives aboard and created one of aviation's most remarkable survival stories.