Sugarcane is one of the most important sugar crops grown commercially and by small-scale farmers in Ethiopia. However, production of this crop is adversely affected by biotic constraints among which sugarcane smut, caused by Sporisorium scitamineum, is one of the most important diseases. Field surveys were conducted once in eight sugar estates (Arjo, Beles, Fincha, Kesem, Kuraz, Metehara, Tendaho, and Wonji) of Ethiopia from 2017 to 2019 to determine the smut distribution, incidence, severity, and association of biophysical factors with smut incidence and severity. A total of 311 fields were assessed in eight sugar estates. Logistic regression was used to analyze the association of independent factors with smut incidence and severity. The results revealed that sugarcane smut prevailed in 62.7% of the fields. Moreover, mean smut incidence and severity varied significantly among the surveyed fields and sugar estates. High smut incidence (>5%) and severity (>25%) were highly associated with Kesem, Kuraz, Metehara, and Tendaho sugar estates; NCo 334, Natal, Mexican, and Guyana sugarcane varieties; altitude of <= 1000 m above sea level (m.a.s.l.); ratoon crop; heavy and intermediate-textured soils; and tillering growth stage. On the other hand, low smut incidence (<= 5%) and severity (<= 25%) had high probability of association with Cuba and Barbados sugarcane varieties; furrow irrigation; altitude of 1001-1500 m.a.s.l.; and weed-free and fertilizer applied fields. In conclusion, the presence of high intensity of sugarcane smut in most surveyed areas implies a stringent need for the development of integrated smut management that incorporates resistant varieties, fungicide and biofungicide seedcane treatment at planting, threshold information for ratooning, ecological-based varietal allocation and recommended crop husbandry for effective and efficient management of smut, and sustainable sugarcane production and productivity in the study areas. Therefore, research should give attention to the development of viable and economically feasible integrated smut management programs.