When safety backfired: How five Spirit jets were disabled by their own protection system
has grounded five aircraft after a fire suppression system accidentally activated inside its maintenance hangar at
Detroit Metropolitan Wayne County Airport
(DTW) on July 4, 2025. The discharge, which may have caused millions of dollars in potential damage, occurred during a severe thunderstorm and is believed to have been triggered by a lightning strike.
The foam system affected two aircraft inside the hangar and three more parked on the adjacent ramp. All five planes have been taken out of service for inspection and cleaning.
Foam incident triggered during thunderstorm
The 126,000 square-foot Spirit maintenance facility, constructed in 2017 at a cost of $32 million, is equipped with a standard foam-based fire suppression system designed to quickly extinguish potential fires. However, such systems are known to be highly corrosive to sensitive aircraft components, including wiring, avionics, and cabin interiors.
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At approximately 5 PM on July 4, the suppression system was unintentionally activated, despite the absence of fire. Foam filled the hangar and spread out through open doors onto the ramp area. Among the affected aircraft were an
Airbus
A321 and an A320 inside the facility, along with three additional aircraft parked outside.
— fl360aero (@fl360aero)
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Cleanup underway, flight operations unaffected
Spirit Airlines confirmed that there were no injuries as a result of the incident and that flight operations have not been disrupted. A contractor has been hired to oversee the cleanup, with first responders assisting in immediate containment efforts.
Industry estimates suggest that even minimal foam exposure can require cleaning costs of around $100,000 per aircraft. In more severe cases, damage could exceed $10 million, depending on the extent of corrosion and required component replacement.
Aircraft fire suppression foam is particularly damaging if not removed within 24 hours, as it can affect electronics, engines, and interior materials. Detailed inspections are currently underway to assess the full extent of damage.
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