You’re sitting at the gate, scrolling through your phone, maybe nursing an overpriced latte, and you see smoke. Not just a little steam from a ground power unit, but thick, acrid black smoke pouring out of a parked aircraft. On July 12, 2013, that exact nightmare scenario played out at the world’s busiest international hub. The London Heathrow Airport fire involving an empty Ethiopian Airlines Boeing 787 Dreamliner didn’t just delay a few flights; it basically sent shockwaves through the entire aviation industry and nearly grounded an entire fleet of next-generation jets.
It was terrifying.
The plane, tail number ET-AOP, was parked at a remote stand. Nobody was on board, which was the only reason we aren't talking about a tragedy involving loss of life. But for Boeing, the timing couldn't have been worse. The Dreamliner had only recently returned to the skies after a high-profile three-month grounding due to battery fires. Everyone assumed the batteries were at it again.
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They weren't.
The chaos on the tarmac that afternoon
When the alarm went off around 4:30 PM, the response was instant. Heathrow’s Fire and Rescue service scrambled. You have to imagine the scene: one of the most sophisticated pieces of machinery on the planet is literally melting from the inside out while parked near Terminal 5. Because the fire was in the upper rear fuselage, it wasn't easy to get to. Firefighters had to rip through the cabin lining to find the source of the heat.
The airport shut down. Both runways closed.
Thousands of passengers were stranded. If you were flying through London that day, your plans were toast. Diversions were sent as far away as Cardiff and Stansted. It took about 90 minutes for the runways to reopen, but the reputational damage to the "plastic plane"—so-called because of its carbon-fiber-reinforced plastic (CFRP) construction—was just beginning.
What actually sparked the London Heathrow Airport fire?
Everyone pointed fingers at the lithium-ion batteries. It was the logical guess. However, the Air Accidents Investigation Branch (AAIB) eventually poked a hole in that theory. The fire wasn't in the belly where the batteries live; it was near the ceiling in the aft section.
The culprit? A tiny component called an Emergency Locator Transmitter (ELT).
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Specifically, it was the Honeywell RESCU 406AF. This device is designed to help rescuers find a plane if it crashes. It’s powered by lithium-manganese dioxide batteries. According to the AAIB’s final report, a crossed wire—likely pinched during assembly—created a short circuit. This caused a "thermal runaway." Basically, the batteries got so hot they ignited the surrounding plastic and insulation.
It’s kind of wild when you think about it. A safety device meant to save lives nearly destroyed a $200 million aircraft.
Why the Dreamliner’s skin made things complicated
The 787 is unique because it isn't made of aluminum. It’s composite. When a traditional metal plane catches fire, the skin usually acts as a bit of a heat sink or melts in a predictable way. With the London Heathrow Airport fire, the composite material actually fed the fire to some extent.
The resin in the carbon fiber can burn.
The AAIB noted that the fire burned through the top of the fuselage, which is something you rarely see in such a short timeframe with aluminum. This sparked a massive debate among aeronautical engineers. How do you repair a "burnt" composite shell? You can't just rivet a patch on it like a 1970s Cessna. Boeing eventually had to fly in a specialized team to perform a first-of-its-kind "composite patch" repair, which was basically a high-tech skin graft for the jet.
The fallout and the fix
The FAA and EASA (the European version) didn't ground the fleet this time, but they did issue an Airworthiness Directive. Every airline had to inspect or remove these ELTs. It was a massive logistical headache for carriers like United, ANA, and British Airways.
- Honeywell had to redesign the wiring.
- Ground crews had to learn new fire-suppression techniques for composites.
- Insurance premiums for new-gen aircraft saw a noticeable "adjustment."
Honestly, the most surprising thing is that ET-AOP is still flying today. After months of painstaking repairs in a custom-built hangar at Heathrow, the aircraft was returned to service. It’s a testament to modern engineering, but it also serves as a reminder that in aviation, even the smallest wire matters.
Lessons for the frequent flyer
When people search for info on the London Heathrow Airport fire, they’re usually looking for reassurance. Is the 787 safe? Yes. The incident led to much more rigorous standards for how small battery-powered devices are stowed in the crown of the fuselage.
If you find yourself caught in an airport emergency, here’s what you actually need to do:
- Stop filming and move. People stayed at the Terminal 5 windows to get TikTok-style footage before TikTok existed. If a plane is on fire near the terminal, there is a non-zero chance of an explosion or toxic fumes. Get to the opposite side of the building.
- Check the "hidden" airports. During the Heathrow shutdown, the smartest travelers immediately booked transit to Gatwick or Luton before the airlines even announced the cancellations. Once the "ground stop" is official, seats on alternative flights vanish in seconds.
- Monitor the AAIB and NTSB reports. If you’re ever nervous about a specific aircraft type, don't read tabloid headlines. Read the actual accident reports. They are dry, but they are factual and free from the "death jet" hyperbole.
The 2013 fire was a fluke of manufacturing—a pinched wire and a bad coincidence. It changed how we look at composite aircraft safety and forced the industry to respect the power of even the smallest lithium battery. Today, Heathrow is better equipped for these "thermal events," but the scorched tarmac of Stand 592 will always be a part of the airport's complicated history.
To stay informed on current Heathrow operations, check the official Heathrow "Live Flight" tracker and the UK Civil Aviation Authority (CAA) safety bulletins, which provide real-time updates on any active ground incidents or airspace restrictions. Using apps like FlightRadar24 can also give you an immediate "big picture" view of whether a ground incident is causing a wider holding pattern for incoming traffic.