Should we be worried about 'cracked windows' after BA flight forced to turn back? Aviation expert reveals the strict safety checks behind every flight

A British Airways flight was forced to turn back mid-air after reports of a cracked passenger window, prompting fresh questions about how safe aircraft really are.

Flight BA2660, which was travelling from Gatwick to Faro, Portugal, returned safely to the airport on Tuesday morning. British Airways described the problem as a ‘minor technical issue’.

The incident comes amid heightened concern over aircraft window safety following a terrifying incident involving a Ryanair flight on July 10.

Ljubiša Karović, 61, from Serbia, was left with his head and shoulders hanging outside a plane at 38,000ft after a window was smashed during a flight from Thessaloniki, Greece, to Memmingen, Germany. His wife desperately clung to his feet as he was partially pulled out of the aircraft.

A fan blade from the Boeing 737-800’s right engine is said to have broken loose shortly after take-off, sending fragments flying into the window and shattering it.

But how dangerous are cracked plane windows – and should passengers be worried?

David Martin, managing director of aerospace tooling supplier Heamar, explained that the rigorous safety checks aircraft undergo mean passengers should be reassured. 

He said: 'Under UK Civil Aviation Authority (CAA) Part 145, an aircraft cannot be released until engineers have the correct facilities, tooling, data and sign-offs.

'Specialist maintenance tools enable frontline teams to carry out checks quickly and correctly, while meeting stringent safety thresholds.'

He added: 'Commercial aircraft are designed and stress-tested to withstand rapid vertical and lateral motion far beyond what's typically encountered in flight.

'In addition, they undergo regular structural maintenance using highly specialised tooling and machinery.

'Every aircraft undergoes both preventative maintenance and detailed post-turbulence inspections to ensure its structural integrity and ongoing safety.

'These checks include examining wing and tail structures, landing gear (particularly if turbulence occurred during takeoff or landing), and cabin fittings.'

David explained that compliance standards are especially high in the UK.

He added that 'everything is calibrated to ensure frontline teams can carry out safety checks quickly and accurately'.

Naturally, reports of incidents such as this have increased fear - but David has warned passengers not to worry.

'Increased social media coverage (including viral videos of recent incidents) has understandably amplified public fears,' he said. 

'But these stringent provisions should help ease concerns and reinforce that the UK's compliance-led system continues to uphold some of the world's most rigorous aviation safety standards.'