Delta crew member’s slide error could cost airline $100,000

Passengers on Delta Flight 3248 received an unusual welcome at the boarding gate in Pittsburgh on Saturday: the unmistakable roar of a giant airbag filling.

One passenger recalls hearing a “boom” as an emergency evacuation slide deployed — a nightmare for crew and passengers, and likely a hefty bill for Delta.

A Delta spokesperson told Business Insider that the incident occurred on an Airbus A220 parked at the gate after its flight from Salt Lake City. The crew member – Delta did not specify whether it was a flight attendant or a pilot – opened the door without first “disarming” it.

Here’s what that means: Before takeoff, flight attendants “arm” the doors so that if they are opened, the slide automatically inflates for emergency evacuation. Think of it like flipping a switch.

After landing, they “disarm” (or turn off) the sliding mechanism, allowing the doors to open normally. If an armed door is opened from the inside, even by simply pulling the handle, the slide bursts within seconds and cannot be stopped.

Although this was an unfortunate mistake, the slide is designed to be easily deployed for a quick escape in the event of a real emergency.

Reconditioning a slide in good condition can cost up to $12,000, with inspections and necessary repairs or replacements adding another $20,000. Adding in the costs of rebooking passengers, providing hotels and taking the plane out of service while the slide is reinstalled, Delta’s total tab could reach $100,000, industry experts say.

The final cost varies depending on the type of aircraft, whether the slide needs to be completely replaced or simply reconditioned, and whether the door or surrounding airframe has been damaged. Slides are made from strong, lightweight materials that usually have a fire-retardant coating.

Airbus previously estimated that a 90-minute delay caused by an accidental slide deployment costs approximately $11,000. If the flight is canceled and passengers must be accommodated, the cost can reach $200,000.

Being off base made things trickier

Plane tracking website FlightRadar24 shows the original plane took off four hours late.

Former Delta pilot Mark Stephens told Business Insider that a mechanic and a replacement slide could have been flown in to fix the problem if there was no solution on site.

He added that swapping the A220 at Pittsburgh — where Delta does not have a major hub — is more logistically tricky than at a hub like Atlanta or Detroit, where spare planes are more readily available to bring passengers in more quickly.

Rebooking may also be easier in a base with more itinerary options.

Delta said passengers on the return flight had been booked for later departures, with hotel rooms provided to those who needed to stay overnight.

This slide deployment error is not uncommon. Airbus said about 30 to 40 involuntary deployments occur each year.

In January, a British Airways crew member accidentally triggered a slide on an Airbus A321 – an error that The Sun reported could cost around $130,000.

And sometimes passengers trigger them. In October, a United Airlines passenger tried to open a door after landing in Houston. The Boeing 737’s door did not open, but it still triggered the evacuation slide.