Airworthiness Directives; The Boeing Company Airplanes

[Federal Register Volume 90, Number 101 (Wednesday, May 28, 2025)]
[Rules and Regulations]
[Pages 22442-22446]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 2025-09506]


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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. FAA-2024-1301; Project Identifier AD-2024-00035-T; 
Amendment 39-23001; AD 2025-06-13]
RIN 2120-AA64


Airworthiness Directives; The Boeing Company Airplanes

AGENCY: Federal Aviation Administration (FAA), DOT.

ACTION: Final rule.

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SUMMARY: The FAA is adopting a new airworthiness directive (AD) for 
certain The Boeing Company Model 787-9 and 787-10 airplanes. This AD 
was prompted by reports that some floor beam side-of-body fittings have 
been manufactured with an incorrect material type. This AD requires 
replacing the incorrectly manufactured floor beam side-of-body 
fittings, inspecting the fuselage frame and fastener holes for damage, 
and repairing any damage. The FAA is issuing this AD to address the 
unsafe condition on these products.

DATES: This AD is effective July 2, 2025.
    The Director of the Federal Register approved the incorporation by 
reference of a certain publication listed in this AD as of July 2, 
2025.

ADDRESSES: 
    AD Docket: You may examine the AD docket at regulations.gov under 
Docket No. FAA-2024-1301; or in person at Docket Operations between 9 
a.m. and 5 p.m., Monday through Friday, except Federal holidays. The AD 
docket contains this final rule, any comments received, and other 
information. The address for Docket Operations is U.S. Department of 
Transportation, Docket Operations, M-30, West Building Ground Floor, 
Room W12-140, 1200 New Jersey Avenue SE, Washington, DC 20590.
    Material Incorporated by Reference:
    <bullet> For Boeing material identified in this AD, contact Boeing 
Commercial Airplanes, Attention: Contractual & Data Services (C&DS), 
2600 Westminster Blvd., MC 110-SK57, Seal Beach, CA 90740-5600; 
telephone 562-797-1717; website myboeingfleet.com.

[[Page 22443]]

    <bullet> You may view this material at the FAA, Airworthiness 
Products Section, Operational Safety Branch, 2200 South 216th St., Des 
Moines, WA. For information on the availability of this material at the 
FAA, call 206-231-3195. It is also available at regulations.gov under 
Docket No. FAA-2024-1301.

FOR FURTHER INFORMATION CONTACT: Joseph Hodgin, Aviation Safety 
Engineer, FAA, 2200 South 216th St., Des Moines, WA 98198; phone: 206-
231-3962; email: [email protected].

SUPPLEMENTARY INFORMATION:

Background

    The FAA issued a notice of proposed rulemaking (NPRM) to amend 14 
CFR part 39 by adding an AD that would apply to certain The Boeing 
Company (Boeing) Model 787-9 and 787-10 airplanes. The NPRM published 
in the Federal Register on May 17, 2024 (89 FR 43344). The NPRM was 
prompted by reports that some floor beam side-of-body fittings have 
been manufactured with an incorrect material type between station 1233 
and station 1593. The incorrect material type is a grade 1 or 2 
commercially pure unalloyed titanium, which has significantly reduced 
strength, fatigue, and damage-tolerance properties compared to the type 
design grade 5 Ti-6AI-4V material.
    In the NPRM, the FAA proposed to require replacing the incorrectly 
manufactured floor beam side-of-body fittings, inspecting the fuselage 
frame and fastener holes for damage, and repairing any damage. The FAA 
is issuing this AD to address the floor beam side-of-body fittings that 
do not meet type design and prevent failure of the fittings. The unsafe 
condition, if not addressed, could result in the inability of the 
surrounding principal structure elements to sustain limit loads and 
damage to critical systems under the floor; these conditions could 
cause loss of control of the airplane. Additionally, in the event of an 
emergency landing or full certified rapid decompression, failure of 
multiple adjacent fittings could result in the inability of the 
passenger floor grid to maintain the loads and could result in serious 
injury or impeded egress for passengers.

Discussion of Final Airworthiness Directive

Comments

    The FAA received comments from nine commenters. The following 
presents the comments received on the NPRM and the FAA's response to 
each comment.
    The Air Line Pilots Association, International and an individual 
supported the NPRM without change.

Request To Use High Frequency Eddy Current (HFEC) as an Alternative 
Inspection Method

    Air Canada, American Airlines, Boeing, KLM Royal Dutch Airlines 
(KLM), Qantas Airways (Qantas), and United Airlines (United) requested 
the FAA allow an HFEC inspection as an alternative inspection method. 
Boeing Alert Requirements Bulletin B787-81205-SB530084-00 RB, Issue 
002, dated September 5, 2024, incorporates HFEC as an optional 
inspection method for determining the type of titanium material. Boeing 
stated that the original X-ray fluorescence spectrometry technology is 
still a valid method, however it is controlled for export in some areas 
and may not be available to all operators.
    FAA agrees to allow HFEC as an alternative inspection method. The 
FAA has changed this AD to require the actions in Boeing Alert 
Requirements Bulletin B787-81205-SB530084-00 RB, Issue 002, dated 
September 5, 2024, instead of Issue 001, and to give credit for 
complying with Boeing Alert Requirements Bulletin B787-81205-SB530084-
00 RB, Issue 001, dated December 8, 2023, before the effective date of 
this AD.

Request To Correct a Part Number

    All Nippon Airways requested that the FAA correct a part number for 
a nut in Boeing Alert Requirements Bulletin B787-81205-SB530084-00 RB, 
Issue 001, dated December 8, 2023, from part number BACN11Z8CK to part 
number BACN11Z9CK.
    The FAA agrees; however, Boeing Alert Requirements Bulletin B787-
81205-SB530084-00 RB, Issue 002, dated September 5, 2024, has corrected 
this typographical error. As stated previously, the FAA has updated 
this AD to require compliance with Boeing Alert Requirements Bulletin 
B787-81205-SB530084-00 RB, Issue 002, dated September 5, 2024, instead 
of Issue 001. No further change to this AD is necessary.

Request To Defer Non-Conforming Parts Replacement

    KLM requested that the FAA allow a grace period after the 
inspection before requiring replacement of any incorrectly manufactured 
floor beam side-of-body fittings. KLM added that a period of 100 flight 
cycles or 750 flight hours (whichever occurs first) would enable 
airlines to plan fitting replacements without the need to cancel 
flights.
    The FAA does not agree. An airplane with an incorrectly 
manufactured floor beam side-of-body fitting does not conform to its 
FAA-certificated type design, nor is it in a condition for safe 
operation, and therefore is not airworthy until a properly approved 
repair has been made. The incorrectly manufactured floor beam side-of-
body fittings are significantly understrength, cannot withstand 
regulatory required loads, and do not provide an adequate level of 
safety. The FAA has not changed this AD in this regard.

Request To Correct a Typographical Error

    United requested that the FAA revise paragraph (e), Unsafe 
Condition, of the proposed AD to remove the extraneous word ``in'' in 
the phrase ``to sustain limit loads and in damage to . . .''
    The FAA agrees to correct the typographical error. The FAA has 
revised paragraph (e) of this AD accordingly.

Request To Correct a Footnote in Tasks of Boeing Alert Requirements 
Bulletin

    United requested that the FAA correct a phrase in footnote 2 of 
Tasks 3, 5, 8, 10, 13, 15, 18, 20, 23, 25, 28, 31, 33, 36, 38, 41, 43, 
46, 48, 51, 53, and 56 in Boeing Alert Requirements Bulletin B787-
81205-SB530084-00 RB, Issue 002, dated September 5, 2024, from 
``Chamfer edges of fastener holes common to the SOB fitting'' to 
``Chamfer edges of fastener holes common to the fuselage frame, once 
installed.'' United Airlines pointed out this error in Issue 001 of the 
document, and that it is also in Issue 002.
    The FAA agrees that the requested change is necessary. The FAA has 
added paragraph (h)(3) of this AD to provide an exception to Boeing 
Alert Requirements Bulletin B787-81205-SB530084-00 RB, Issue 002, dated 
September 5, 2024, to correct the language in the footnote.

Request To Correct a Part Quantity

    United requested that the FAA change the quantity of ``1'' spacer 
in Table 1 of Tasks 3, 5, 8, 10, 13, 15, 18, 20, 23, 25, 28, 31, 33, 
36, 38, 41, 43, 46, 48, 51, 53, and 56 in Boeing Alert Requirements 
Bulletin B787-81205-SB530084-00 RB, Issue 001, dated December 8, 2023, 
to match the quantity ``0'' to ``3'' in the footnote.
    The FAA agrees with the comment. However, Boeing Alert Requirements 
Bulletin B787-81205-SB530084-00 RB, Issue 002, dated September 5, 2024, 
which is incorporated by reference in this AD instead of Issue 001, 
contains

[[Page 22444]]

the correct spacer quantity. No further change to this AD is necessary.

Concern About Spare Parts Availability

    Qantas stated that it supported the proposed requirements but 
expressed its concern regarding spare parts availability. Quantas 
requested assurance that Boeing has sufficient spares to meet the 
expected demand.
    Boeing Alert Service Bulletin B787-81205-SB530084-00, Issue 002, 
dated September 5, 2024, contains information regarding parts 
availability and order lead times. The FAA acknowledges the commenter's 
concern but cannot base its AD action on whether spare parts are 
available or can be produced.

Concern About Quality Control

    Qantas expressed concern regarding whether the quality control 
issues with the non-conforming titanium fittings have been addressed.
    As part of the safety investigation related to this AD, all parts 
under the Boeing quality system were inspected for conformity. In 
addition, Boeing performed a root cause analysis and took corrective 
actions to prevent reoccurrence of similar issues.

Conclusion

    The FAA reviewed the relevant data, considered any comments 
received, and determined that air safety requires adopting this AD as 
proposed. Accordingly, the FAA is issuing this AD to address the unsafe 
condition on these products. Except for changes described previously, 
this AD is adopted as proposed in the NPRM. None of the changes will 
increase the economic burden on any operator.

Material Incorporated by Reference Under 1 CFR Part 51

    The FAA reviewed Boeing Alert Requirements Bulletin B787-81205-
SB530084-00 RB, Issue 002, dated September 5, 2024. This material 
specifies performing an X-ray fluorescence spectrometer inspection or 
an HFEC inspection of the floor beam side-of-body fittings between 
station 1233 and station 1593 to determine whether the fitting was 
manufactured with type design grade 5 Ti-6AI-4V material. 
Alternatively, operators may replace all floor beam side-of-body 
fittings between station 1233 and station 1593 with fittings made of 
the correct material without performing an inspection. For any floor 
beam side-of-body fitting that needs replacement, this material 
specifies inspecting the fuselage frame and fuselage fastener holes for 
damage, repairing any damage, and installing a floor beam side-of-body 
fitting made of the correct material.
    This material is reasonably available because the interested 
parties have access to it through their normal course of business or by 
the means identified in the ADDRESSES section.

Costs of Compliance

    The FAA estimates that this AD affects 60 airplanes of U.S. 
registry. The FAA estimates the following costs to comply with this AD:

                                            Estimated Costs--Option 1
----------------------------------------------------------------------------------------------------------------
                                                                          Cost per
              Action                      Labor cost        Parts cost    airplane      Cost on U.S. operators
----------------------------------------------------------------------------------------------------------------
X-ray fluorescence spectrometer     77 work-hours x $85             $0       $6,545  Up to $392,700.
 inspection or.                      per hour = $6,545.
HFEC inspection to determine
 material type.
----------------------------------------------------------------------------------------------------------------


                        Estimated Costs--Option 2
------------------------------------------------------------------------
                                                               Cost per
            Action                Labor cost     Parts cost    airplane
------------------------------------------------------------------------
Replace all affected floor     527 work-hours      $218,250     $263,045
 beam side-of-body fittings     x $85 per hour
 and inspect for damage.        = $44,795.
------------------------------------------------------------------------

    The FAA estimates the following costs to do any replacements that 
would be required based on the results of the inspection. The agency 
has no way of determining the number of aircraft that might need this 
replacement:

                     On-Condition Costs for Option 1
------------------------------------------------------------------------
                                                               Cost per
            Action                Labor cost     Parts cost    fitting
------------------------------------------------------------------------
Replace floor beam side-of-    18 work-hours x       $8,730      $10,260
 body fitting and inspect for   $85 per hour =
 damage (per fitting).          $1,530.
------------------------------------------------------------------------

    The extent of damage found during the inspection done when the 
fittings are replaced could vary significantly from airplane to 
airplane. The FAA has no way of determining how much damage may be 
found on each airplane, the cost to repair damaged parts on each 
airplane, or the number of airplanes that may require repair.
    The FAA has included all known costs in its cost estimate. 
According to the manufacturer, however, some of the costs of this AD 
may be covered under warranty, thereby reducing the cost impact on 
affected operators.

Authority for This Rulemaking

    Title 49 of the United States Code specifies the FAA's authority to 
issue rules on aviation safety. Subtitle I, section 106, describes the 
authority of the FAA Administrator. Subtitle VII: Aviation Programs, 
describes in more detail the scope of the Agency's authority.
    The FAA is issuing this rulemaking under the authority described in 
Subtitle VII, Part A, Subpart III, Section 44701: General requirements. 
Under that section, Congress charges the FAA with promoting safe flight 
of civil aircraft in air commerce by prescribing regulations for 
practices, methods, and procedures the Administrator finds necessary 
for safety in air commerce.

[[Page 22445]]

This regulation is within the scope of that authority because it 
addresses an unsafe condition that is likely to exist or develop on 
products identified in this rulemaking action.

Regulatory Findings

    This AD will not have federalism implications under Executive Order 
13132. This AD will not have a substantial direct effect on the States, 
on the relationship between the national government and the States, or 
on the distribution of power and responsibilities among the various 
levels of government.
    For the reasons discussed above, I certify that this AD:
    (1) Is not a ``significant regulatory action'' under Executive 
Order 12866,
    (2) Will not affect intrastate aviation in Alaska, and
    (3) Will not have a significant economic impact, positive or 
negative, on a substantial number of small entities under the criteria 
of the Regulatory Flexibility Act.

List of Subjects in 14 CFR Part 39

    Air transportation, Aircraft, Aviation safety, Incorporation by 
reference, Safety.

The Amendment

    Accordingly, under the authority delegated to me by the 
Administrator, the FAA amends 14 CFR part 39 as follows:

PART 39--AIRWORTHINESS DIRECTIVES

0
1. The authority citation for part 39 continues to read as follows:

    Authority: 49 U.S.C. 106(g), 40113, 44701.


Sec.  39.13  [Amended]

0
2. The FAA amends Sec.  39.13 by adding the following new airworthiness 
directive:

2025-06-13 The Boeing Company: Amendment 39-23001; Docket No. FAA-
2024-1301; Project Identifier AD-2024-00035-T.

(a) Effective Date

    This airworthiness directive (AD) is effective July 2, 2025.

(b) Affected ADs

    None.

(c) Applicability

    This AD applies to The Boeing Company Model 787-9 and 787-10 
airplanes, certificated in any category, as identified in Boeing 
Alert Requirements Bulletin B787-81205-SB530084-00 RB, Issue 002, 
dated September 5, 2024.

(d) Subject

    Air Transport Association (ATA) of America Code 53, Fuselage.

(e) Unsafe Condition

    This AD was prompted by reports that some floor beam side-of-
body fittings have been manufactured with an incorrect material type 
between station 1233 and station 1593. The FAA is issuing this AD to 
address the floor beam side-of-body fittings that do not meet type 
design and prevent failure of the fittings. The unsafe condition, if 
not addressed, could result in the inability of the surrounding 
principal structure elements to sustain limit loads and damage to 
critical systems under the floor; these conditions could cause loss 
of control of the airplane. Additionally, in the event of an 
emergency landing or full certified rapid decompression, failure of 
multiple adjacent fittings could result in the inability of the 
passenger floor grid to maintain the loads and could result in 
serious injury or impeded egress for passengers.

(f) Compliance

    Comply with this AD within the compliance times specified, 
unless already done.

(g) Required Actions

    Except as specified in paragraph (h) of this AD: At the 
applicable times specified in the ``Compliance'' paragraph of Boeing 
Alert Requirements Bulletin B787-81205-SB530084-00 RB, Issue 002, 
dated September 5, 2024, do all applicable actions identified in, 
and in accordance with, the Accomplishment Instructions of Boeing 
Alert Requirements Bulletin B787-81205-SB530084-00 RB, Issue 002, 
dated September 5, 2024.

    Note 1 to paragraph (g): Guidance for accomplishing the actions 
required by this AD can be found in Boeing Alert Service Bulletin 
B787-81205-SB530084-00, Issue 002, dated September 5, 2024, which is 
referred to in Boeing Alert Requirements Bulletin B787-81205-
SB530084-00 RB, Issue 002, dated September 5, 2024.

(h) Exceptions to Service Information Specifications

    (1) Where the ``Boeing Recommended Compliance Time'' column in 
the tables under the ``Compliance'' paragraph of Boeing Alert 
Requirements Bulletin B787-81205-SB530084-00 RB, Issue 002, dated 
September 5, 2024, refers to ``the Issue 001 date of Requirements 
Bulletin B787-81205-SB530084-00 RB,'' this AD requires using the 
effective date of this AD.
    (2) Where Boeing Alert Requirements Bulletin B787-81205-
SB530084-00 RB, Issue 002, dated September 5, 2024, specifies 
contacting Boeing for repair instructions, this AD requires doing 
the repair before further flight using a method approved in 
accordance with the procedures in paragraph (i) of this AD.
    (3) Where footnote [2] in Tasks 3, 5, 8, 10, 13, 15, 18, 20, 23, 
25, 28, 31, 33, 36, 38, 41, 43, 46, 48, 51, 53, and 56 of Boeing 
Alert Requirements Bulletin B787-81205-SB530084-00 RB, Issue 002, 
dated September 5, 2024, uses the phrase ``Chamfer edges of fastener 
holes common to the SOB fitting,'' for this AD, replace that phrase 
with ``Chamfer edges of fastener holes common to the fuselage frame, 
once installed.''

(i) Credit for Previous Actions

    This paragraph provides credit for the actions specified in 
paragraph (g) of this AD, if those actions were performed before the 
effective date of this AD using Boeing Alert Requirements Bulletin 
B787-81205-SB530084-00 RB, Issue 001, dated December 8, 2023.

(j) Alternative Methods of Compliance (AMOCs)

    (1) The Manager, AIR-520, Continued Operational Safety Branch, 
FAA, has the authority to approve AMOCs for this AD, if requested 
using the procedures found in 14 CFR 39.19. In accordance with 14 
CFR 39.19, send your request to your principal inspector or 
responsible Flight Standards Office, as appropriate. If sending 
information directly to the manager of the certification office, 
send it to the attention of the person identified in paragraph 
(k)(1) of this AD. Information may be emailed to: [email protected].
    (2) Before using any approved AMOC, notify your appropriate 
principal inspector, or lacking a principal inspector, the manager 
of the responsible Flight Standards Office.
    (3) An AMOC that provides an acceptable level of safety may be 
used for any repair, modification, or alteration required by this AD 
if it is approved by The Boeing Company Organization Designation 
Authorization (ODA) that has been authorized by the Manager, AIR-
520, Continued Operational Safety Branch, FAA, to make those 
findings. To be approved, the repair method, modification deviation, 
or alteration deviation must meet the certification basis of the 
airplane, and the approval must specifically refer to this AD.

(k) Related Information

    (1) For more information about this AD, contact Joseph Hodgin, 
Aviation Safety Engineer, FAA, 2200 South 216th St., Des Moines, WA 
98198; phone: 206-231-3962; email: [email protected].
    (2) Material identified in this AD that is not incorporated by 
reference is available at the address specified in paragraph (l)(3) 
of this AD.

(l) Material Incorporated by Reference

    (1) The Director of the Federal Register approved the 
incorporation by reference of the service information listed in this 
paragraph under 5 U.S.C. 552(a) and 1 CFR part 51.
    (2) You must use this service information as applicable to do 
the actions required by this AD, unless the AD specifies otherwise.
    (i) Boeing Alert Requirements Bulletin B787-81205-SB530084-00 
RB, Issue 002, dated September 5, 2024.
    (ii) [Reserved]
    (3) For service information, contact Boeing Commercial 
Airplanes, Attention: Contractual & Data Services (C&DS), 2600 
Westminster Blvd., MC 110-SK57, Seal

[[Page 22446]]

Beach, CA 90740-5600; telephone 562-797-1717; website 
myboeingfleet.com.
    (4) You may view this service information at the FAA, 
Airworthiness Products Section, Operational Safety Branch, 2200 
South 216th St., Des Moines, WA. For information on the availability 
of this material at the FAA, call 206-231-3195.
    (5) You may view this material at the National Archives and 
Records Administration (NARA). For information on the availability 
of this material at NARA, visit www.archives.gov/federal-register/cfr/ibr-locations or email [email protected].

    Issued on March 24, 2025.
Peter A. White,
Deputy Director, Integrated Certificate Management Division, Aircraft 
Certification Service.
[FR Doc. 2025-09506 Filed 5-27-25; 8:45 am]
BILLING CODE 4910-13-P

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