Flight Details
Aircraft Type: Boeing 787-9 Dreamliner Operator: TUI Airways Registration: G-TUIN Flight Number: BY601 Route: Orlando Melbourne International Airport (MLB), Florida, USA to Birmingham Airport (BHX), United Kingdom Date of Incident: 18 April 2025 Total Occupants: Not specified; typical 787-9 capacity ~296 passengers and crew Weather Conditions: Daytime operation; visual meteorological conditions reported
Introduction
On 18 April 2025, a TUI Airways Boeing 787-9 bound for Birmingham, UK rejected takeoff at high speed from Orlando Melbourne’s runway 09R. The crew brought the aircraft to a halt on the runway, assessed the situation, and determined no emergency services were initially required. The aircraft then attempted to vacate the runway via taxiway C, but during the turn onto taxiway A, the right main landing gear rolled off the paved surface and onto adjacent grass, prompting the crew to stop and request assistance. The aircraft remains grounded at Orlando Melbourne approximately 40 hours after the event, pending technical inspection and assessment of possible landing gear or structural damage.
Sequence of Events
Flight BY601 was scheduled to depart Orlando Melbourne for an overnight transatlantic flight to Birmingham. The aircraft taxied to runway 09R and commenced its takeoff roll. During the high-speed acceleration phase—likely above 80 knots and approaching V1—the crew executed a rejected takeoff (RTO).
Reasons for the rejected takeoff have not yet been publicly disclosed, but common triggers at high speed include:
Engine instrument anomalies (e.g. EGT exceedance, N1/N2 instability) ECAM warnings for systems failure (e.g. brakes, hydraulics, doors, config) Birdstrike or runway FOD (foreign object debris) Spurious stall, airspeed disagreement, or takeoff configuration alerts
Following the RTO, the aircraft came to a complete stop on the runway. The crew communicated with tower that no emergency services were required, and that they intended to vacate the runway and return to the holding point.
ATC cleared the aircraft to taxi down runway 09R and exit via turn-off C, turning right onto taxiway A. During the right-hand turn from taxiway C onto A, the right main landing gear exited the paved taxiway surface and came to rest on grass. The aircraft stopped immediately, and the crew then requested ground assistance.
There was no report of structural damage, fire, or injuries, though potential gear stress or minor gear displacement could not be ruled out.
Crew & Communication
The flight crew handled the sequence in accordance with Boeing procedures for a high-speed RTO. The fact that the crew opted to continue taxiing and return to the holding point suggests the initial fault prompting the abort was not considered critical or visually obvious (e.g. fire, tyre burst).
The deviation of the main gear during a slow-speed taxi turn may indicate:
Tight turning radius with insufficient wing walker or visual clearance Poor taxiway edge visibility Soft edge subsidence, or unexpected differential braking Lack of centreline adherence in a widebody aircraft at a regional airport
Post-excursion, the crew communicated promptly with ground control and remained in position pending technical and towing support.
Aircraft Systems & Technical Analysis
The Boeing 787-9 is equipped with carbon brakes, electrically actuated systems, and advanced weight-on-wheels sensors. During an RTO from high speed, the following systems are likely to have been activated:
Auto-brake system triggering maximum deceleration Spoiler deployment Thrust reversers (unless below 80 knots) Brake temperature monitoring post-stop
No brake fire, tyre burst, or structural anomalies were immediately visible, but the aircraft’s position on grass may have affected the gear’s stress load depending on ground firmness and angle of departure from the taxiway.
Ground support teams will have conducted:
Inspection of tyre and wheel assemblies for side-load stress Landing gear truck beam and shock strut examination Re-alignment of the aircraft for towing back to stand Pavement integrity checks for edge breakdown
Depending on the angle and load at time of departure from the paved surface, the gear may require borescope or alignment checks before return to service.
Passenger Experience & Cabin Conditions
Passengers would have experienced a sudden deceleration followed by a full stop on the runway. Cabin crew would have secured the cabin per rejected takeoff SOP, and likely advised passengers to remain seated.
No emergency slides were deployed, and passengers were not evacuated. After the runway excursion during taxi, passengers remained on board during the wait for assistance. Cooling, lighting, and ECS systems remained operational.
The airline cancelled the flight, and passengers were later rebooked or accommodated, pending aircraft inspection and logistical rearrangements.
Emergency Response & Aftermath
Following the excursion, ground emergency services responded to the scene to evaluate gear position, environmental risk (fuel, hydraulic leakage), and passenger safety. No further damage was reported, and the aircraft remained stationary while coordination between airport operations and TUI engineering took place.
The aircraft, registration G-TUIN, is currently still grounded at Orlando Melbourne pending full engineering sign-off.
Flight BY601 was officially cancelled and removed from the departure board. TUI Airways has not issued a full technical statement at the time of writing.
Investigation Status
The event has been reported to the FAA, who may conduct a routine incident review given the rejected takeoff and subsequent ground excursion. The UK CAA will be informed due to the UK registry of the aircraft.
TUI Airways engineering teams, in coordination with Boeing, will review:
Quick access recorder (QAR) data for rejected takeoff cause Brake and thrust system data Taxiway turning data, including GPS ground track Structural stress readings from the main gear sensor suite
Root Cause & Contributing Factors
While the root cause of the RTO is not yet known, potential causes include:
Takeoff configuration warning (flap, trim, rudder, spoiler) Engine performance anomaly (surge, EGT spike) Birdstrike or FOD detection Navigation system fault
The taxiway excursion likely resulted from a tight turn radius, possibly compounded by aircraft weight, misjudged geometry, or poor ground markings at a regional airport less commonly used for widebody aircraft.
Safety Recommendations & Industry Impact
Pending the investigation’s outcome, potential safety considerations may include:
Enhanced taxiway markings and wingtip clearance guidance for widebodies at regional airports Review of airport geometry and suitability for long-haul aircraft Procedural emphasis on rejected takeoff judgment at high-speed thresholds Taxi risk assessments post-abort prior to repositioning
Conclusion
The incident involving TUI Airways Boeing 787-9 G-TUIN at Orlando Melbourne highlights the complexity of managing a high-speed rejected takeoff and post-abort taxi procedures. While the aircraft avoided runway overrun or inflight failure, the subsequent taxiway deviation introduces a new layer of operational and engineering scrutiny.
With no injuries or damage reported, the event remains a contained operational anomaly. However, investigations will provide insight into rejected takeoff decision-making and the challenges of operating widebody aircraft from regional airfields.
Disclaimer
This article is based on publicly available information and reports at the time of writing. While every effort has been made to ensure accuracy, we cannot guarantee the completeness of the information provided.
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