How a Delta crew member’s emergency slide mistake could cost as much as $100,000

• A Delta crew member accidentally deployed an Airbus A220 emergency evacuation slide on Saturday.
• They did not “disarm” the door before lifting the handle.
• Industry experts say the cost could be upward of $100,000, while Airbus estimated up to $200,000.

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

A passenger recalled hearing a “boom” when an emergency evacuation slide deployed — a nightmare for the crew and passengers, and a likely expensive bill for Delta.

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

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

After landing, they “disarm” (or switch off) the slide mechanism, allowing the doors to be opened normally. If an armed door is opened from the inside — even just by pulling the handle — the slide bursts out in seconds, and it can’t be stopped.

While an unfortunate mistake, the slide is designed to be easily deployed for a quick escape in a real emergency.

Repacking an undamaged slide can cost up to $12,000, with inspections and any necessary repairs or replacements adding an additional $20,000. Adding 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, according to industry experts.

The final cost varies depending on the aircraft type, whether the slide requires full replacement or just repackaging, and whether the door or surrounding airframe has been damaged. The slides are made from strong, lightweight materials that typically have a fire-resistant coating.

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

Being outside a base made things trickier

The aircraft tracking website FlightRadar24 shows the original aircraft took off four hours late.

Former Delta pilot Mark Stephens told Business Insider that a mechanic and replacement slide may have been flown in to address the problem if there wasn’t a fix on-site.

He added that swapping the A220 in Pittsburgh — where Delta doesn’t have a major hub — is logistically trickier than at a hub like Atlanta or Detroit, where spare planes are more readily available to get passengers on their way more quickly.

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

Delta said passengers on the return flight were rebooked on later departures, with hotel rooms provided to those who had to stay overnight.

This slide deployment mistake is not unheard of. Airbus said that roughly 30 to 40 inadvertent deployments happen each year.

In January, a British Airways crew member accidentally set off a slide on an Airbus A321 — an error that The Sun reported could cost about $130,000.

And sometimes passengers set them off. In October, a United Airlines passenger tried to open a door after landing in Houston. The Boeing 737 door didn’t open, but it still triggered the evacuation slide.

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