The Charity
Aviation
Maritime
During pre-flight inspection I accidentally walked into a flap that was in the down position receiving a serious cut to the top of my head. I had to have 9 staples to close the wound.
Aircraft can be dangerous with many sharp edges. Be extra careful during pre-flight checks. During my career in aviation (25 years) I have seen many injuries received by others during pre-flight inspections, but fortunately I have escaped injury until now.

Lessons Learned: The main human factors that I identified from this incident were a lapse in concentration, not being 100% diligent on my pre-flight inspection and not remembering the hazards that are present whilst being around aircraft. Other factors could also be involved in similar incidents such as time pressures, distractions etc.
As a flight instructor I am using my new scar and experience in pre-flight Threat & Error Management (TEM) briefings with students and other pilots to highlight the threats that are present whilst being airside around aircraft and how to mitigate and avoid the dangers.
All images reproduced by kind consent of reporter
This was an open and honest report describing an event that could happen to anyone, and probably has to many of us, albeit not always with such a dramatic outcome. The reporterâs reflections contain valuable human factors insights about operating around aircraft, particularly during pre-flight checks. Their willingness to share this painful lesson will no doubt help others avoid similar mishaps.
Beyond the obvious message – âtry not to bump into thingsâ – there are several wider safety considerations. Far more injuries occur on the ground than in the air, yet these are often under-reported. Although technically an injury does not become a âreportable incidentâ until the pilot enters the aircraft with the intention of flight, such occurrences should still be reported so that common themes can be identified and safety improvements made.
Working around aircraft exteriors can be surprisingly hazardous. Walk-rounds should never be rushed; it is far better to find a defect or problem on the ground than in the air. Student pilots should be briefed about external hazards during initial and differences training, and pilots should remain alert to the particular features of their own aircraft. When carrying passengers, a short, calm briefing about key external hazards can help prevent accidents, as noted in Safety Sense Leaflet 2 â Care of Passengers in GA, which was highlighted in CHIRP GA FEEDBACK Edition 105. Pilots have a duty of care for their passengers and should always accompany them on dispersal; inadequate briefing might even have implications for insurance liability in the event of injury.
Typical hazards include flaps, aerials, pitot tubes and tailplanes that can be walked into; fluids that can splash into eyes; or steps on low-wing aircraft that can cause falls. Many professionals working airside wear bump caps, which can be purchased relatively cheaply (ÂŁ15-ÂŁ20) and may be worth considering for GA use. Similar arguments could apply to other forms of personal protective equipment when appropriate.
Itâs not just people who can get hurt – any impact can also damage the aircraft, particularly older ones where skin or structure may already be fragile. Care, time and situational awareness during pre-flight inspection are essential defences in preventing both personal and aircraft injury. Finally, donât forget that if youâre distracted during your pre-flight for any reason, itâs good practice to go back to the beginning or a known break point and start again, rather than try to carry on from where you stopped.
Human Factors Considerations
The following âDirty Dozenâ and other Human Factors were a key part of the CHIRP discussions about this report and are intended to provide food for thought when considering aspects that might be pertinent in similar circumstances.
Positive factors:
Negative factors / latent conditions: