A Boeing 787-9 Dreamliner operating flight TOM156 from Manchester Airport (MAN) to Punta Cana (PUJ) made an immediate return to Manchester after experiencing smoke in the cockpit on April 19, 2024. Due to the urgency of the situation, G-TUIL returned to the airport without dumping fuel, leading to an overweight landing. Our friends at Airliners Live captured the aircraft’s return, you can view the footage below.
All aircraft have a maximum landing weight (MLW). This is a mass (typically measured in tonnes) which the aircraft should reach before landing in order to stop in the appropriate distance and not place excess stress on the aircraft itself. Most widebody aircraft are equipped with fuel dumping systems, allowing them to jettison unused fuel and reduce the aircraft’s mass to below its maximum landing weight.
Most narrowbody aircraft do not have the ability to dump fuel. This is because many of them have a maximum takeoff weight (MTOW) equal to their maximum landing weight, meaning that in the event of returning to an airport after takeoff, they can land immediately.
What happens when a widebody aircraft encounters an emergency which requires them to return to the airport immediately after takeoff, leaving them with no time to dump their excess fuel? Let’s take a look.
Which situations might require an overweight landing?
There are several scenarios that might necessitate a widebody jet to return to an airport shortly after takeoff without having the opportunity to dump fuel. Here are some common reasons:
- Alarms – indicating issues in the cockpit, cabin, or cargo hold, such as smoke or fire alarms, require immediate attention. This was the situation faced by the crew of TOM156.
- Medical emergencies – a passenger or crew member with a severe medical issue that endangers life may facilitate an immediate landing.
- Technical problems – such as issues with the aircraft’s engines, hydraulics, or critical systems that manifest shortly after takeoff can prompt a return to the airport.
- Cabin pressurization failures – Whilst aircraft can fly safely without pressurization up to around 10,000 feet, some situations may require an immediate return without fuel dumping.
- Bird strikes – If a bird strike occurs during or shortly after takeoff and it is suspected to have caused significant damage to the aircraft, particularly to the engines, a prompt return to the departure airport is necessary.
- Security concerns – Threats or security breaches aboard the aircraft may also lead to an immediate return to the departure point without the time or space to safely dump fuel.
What are the considerations taken when landing an overweight aircraft?
Landing technique
In a scenario where an aircraft must land overweight, pilots rely on specific techniques to manage the additional weight. The approach speed is generally higher to maintain control, which necessitates precise handling during touchdown. Pilots aim for a ‘firm’ landing rather than a ‘soft’ one to ensure the aircraft’s weight is quickly and effectively supported by the landing gear and not prolonged in a floating phase, which could lead to runway overshoot.
To aid in deceleration, pilots make full use of the aircraft’s braking systems, including maximum deployment of reverse thrust and speed brakes. It is essential to manage the reverse thrust carefully to avoid stress on the aircraft structure.
Weight and stopping distance
The stopping distance of an aircraft is directly affected by its weight. An overweight aircraft has more inertia and requires a greater distance to come to a complete stop. The use of reverse thrust and brakes must be optimized to handle this increased stopping distance. Pilots also have to be mindful of the runway length and condition; for instance, a wet or icy runway might further impede braking effectiveness and require even more distance for a safe stop.
Braking
The higher landing speed increases the stress on the tires and brakes, which can lead to higher wear and risk of failure if not managed correctly. Pilots must ensure that the braking is done steadily and evenly to prevent potential blowouts or skidding, and use the brake fans appropriately.
Brake fans are designed to cool the brakes of an aircraft after landing, a time when the brakes can reach extremely high temperatures due to the friction generated in slowing and stopping the aircraft. The use of brake fans helps to prevent overheating, which can lead to brake wear or even failure. They are installed as part of the aircraft’s landing gear system, specifically around the brake assemblies. When activated, these fans blow air directly onto the brakes, enhancing the natural cooling process by increasing the rate of heat dissipation. This forced-air cooling is crucial because it reduces the time it takes for the brakes to cool to a safe temperature, allowing the aircraft to be ready for another flight sooner.
Brake fans are typically used in situations where an aircraft has to perform quick turnarounds, such as in busy commercial airports. They are also crucial when an aircraft lands with high kinetic energy, such as in the case of an overweight landing. In these scenarios, the brakes work harder and thus generate more heat. Additionally, in hot weather conditions, the ambient temperatures can impede the natural cooling of the brakes, making the role of brake fans even more significant.
Post-landing inspections
After an overweight landing, the aircraft must undergo a thorough inspection to assess any potential damage. This inspection is crucial as the added stress on the aircraft’s structure and landing gear can lead to issues that may not be immediately apparent. Key areas of focus include:
- Landing Gear – The gear must be checked for any signs of structural weakness or hydraulic leaks. Overweight landings can strain the shock absorbers and joints, which might compromise their effectiveness.
- Tires and Brakes – These components are likely to exhibit the most wear due to the increased friction and heat generated during an overweight landing. Technicians look for any signs of melting, tears, or excessive wear in the tire treads and check the brake pads for degradation or uneven wear.
- Structural Integrity – The aircraft’s fuselage and wings are inspected for any signs of stress fractures or deformation. Special attention is given to the wing roots and attachment points, as these bear a significant load during landing.
- Engine Performance – The engines are checked for any abnormalities in their operation, especially if maximum reverse thrust was used during the landing. This includes examining the engine mounts and exhaust systems for any signs of damage or unusual wear.
Whilst overweight landings are rare, these techniques and procedures are combined with extensive crew training to ensure that the aircraft can make a safe and immediate return should it be required.
Cover photo: Charles Cunliffe, JetPhotos.
![An example full flight summary response from the Flightradar24 API: { "data": [ { "fr24_id": "0987654321", "flight": "SK1415", "callsign": "SAS1415", "operated_as": "SAS", "painted_as": "SAS", "type": "A20N", "reg": "SE-DOY", "orig_icao": "ESSA", "orig_iata": "ARN", "datetime_takeoff": "2023-01-27T05:15:22", "runway_takeoff": "12R", "dest_icao": "EKCH", "dest_iata": "CPH", "dest_icao_actual": "EPWA", "dest_iata_actual": "WAW", "datetime_landed": "2023-01-27T06:15:10", "runway_landed": "27L", "flight_time": 3600, "actual_distance": 1007.74, "circle_distance": 6245, "category": "Passenger", "hex": "4A91F9", "first_seen": "2023-01-27T05:06:22", "last_seen": "2023-01-27T06:18:10", "flight_ended": "true" } ] }](https://www.flightradar24.com/blog/wp-content/uploads/2025/04/Flight-summary-API-cover-300x148.jpg)
![An example full flight summary response from the Flightradar24 API: { "data": [ { "fr24_id": "0987654321", "flight": "SK1415", "callsign": "SAS1415", "operated_as": "SAS", "painted_as": "SAS", "type": "A20N", "reg": "SE-DOY", "orig_icao": "ESSA", "orig_iata": "ARN", "datetime_takeoff": "2023-01-27T05:15:22", "runway_takeoff": "12R", "dest_icao": "EKCH", "dest_iata": "CPH", "dest_icao_actual": "EPWA", "dest_iata_actual": "WAW", "datetime_landed": "2023-01-27T06:15:10", "runway_landed": "27L", "flight_time": 3600, "actual_distance": 1007.74, "circle_distance": 6245, "category": "Passenger", "hex": "4A91F9", "first_seen": "2023-01-27T05:06:22", "last_seen": "2023-01-27T06:18:10", "flight_ended": "true" } ] }](https://www.flightradar24.com/blog/wp-content/uploads/2025/04/Flight-summary-API-cover-768x378.jpg)
