Airworthiness Directives; the Boeing Company Airplanes

[Federal Register Volume 90, Number 105 (Tuesday, June 3, 2025)]
[Rules and Regulations]
[Pages 23425-23427]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 2025-10061]


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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. FAA-2025-0005; Project Identifier AD-2024-00646-T; 
Amendment 39-23051; AD 2025-11-05]
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 787-8, 787-9, and 787-10 airplanes. 
This AD was prompted by reports of multiple supplier notices of 
escapement (NOEs) indicating that seat track splice fittings were 
possibly manufactured with an incorrect titanium alloy material. This 
AD requires an inspection of seat track splice fittings to determine 
the material and applicable on-condition actions. The FAA is issuing 
this AD to address the unsafe condition on these products.

DATES: This AD is effective July 8, 2025.
    The Director of the Federal Register approved the incorporation by 
reference of a certain publication listed in this AD as of July 8, 
2025.

ADDRESSES: 
    AD Docket: You may examine the AD docket at regulations.gov under 
Docket No. FAA-2025-0005; 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.
    <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-2025-0005.

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 Model 787-8, 787-9, and 787-10 airplanes. The NPRM was 
published in the Federal Register on January 17, 2025 (90 FR 5756). The 
NPRM was prompted by reports of multiple supplier NOEs indicating that 
seat track splice fittings were possibly manufactured with an incorrect 
titanium alloy material. In the NPRM, the FAA proposed to require an 
inspection of seat track splice fittings to determine the material and 
applicable on-condition actions. The FAA is issuing this AD to address 
seat track splice fittings manufactured with an incorrect titanium 
alloy material. The unsafe condition, if not addressed, could result in 
failure of the seat track splice fittings, and could result in serious 
injury to seated occupants as a result of adverse effects on emergency 
egress and structural capability to react to emergency landing loads.

Discussion of Final Airworthiness Directive

Comments

    The FAA received comments from four anonymous commenters who 
supported the NPRM without change.
    The FAA received additional comments from three commenters, 
including Boeing, Air New Zealand, and the Foundation for Aviation 
Safety. The following presents the comments received on the NPRM and 
the FAA's response to each comment.

Request for Clarification of Root Cause

    The Foundation for Aviation Safety requested an explanation of the 
root cause of the use of the incorrect titanium alloy material, asked 
how its use was discovered and why the original process wasn't 
effective in identifying use of the incorrect material, and 
clarification on the preventive measures to keep this from happening 
again.
    The FAA provides the following clarification. Boeing and the FAA 
have received reports of multiple supplier NOEs indicating that seat 
track splice fittings were possibly manufactured with an incorrect 
titanium alloy material. The FAA has determined the actions specified 
in this AD must be done to address the unsafe condition. The root cause 
of the use of the incorrect titanium alloy material is still under 
investigation. The FAA is working with Boeing to address the root 
cause. No change to this AD is necessary as a result of this comment.

Request To Add Exception

    Boeing and Air New Zealand requested an exception be added to the 
proposed AD to allow use of collars having part number (P/N) 
BACC30BS10K for tasks 17 and 18 of Boeing Alert Requirements Bulletin 
B787-81205-SB530086-00 RB, Issue 001, dated October 18, 2024. Air New 
Zealand stated tasks 17 and 18 of Boeing Alert Requirements Bulletin 
B787-81205-SB530086-00 RB, Issue 001, dated October 18, 2024, and 
Boeing Alert Service Bulletin B787-81205-SB530086-00, Issue 001, dated 
October 18, 2024, use collars having P/N BACC30BS10S. Air New Zealand 
further pointed out that table 18 of paragraph 3.A., Kits/Parts, of 
Boeing Alert Service Bulletin B787-81205-SB530086-00, Issue 001, dated 
October 18, 2024, lists collars having P/N BACC30BS10K for tasks 17 and 
18. Boeing confirmed that both collars are

[[Page 23426]]

structurally and functionally equivalent at these locations.
    The FAA agrees with this request for the reasons provided. 
Paragraph (h) of the proposed AD has been reidentified as paragraph 
(h)(1) in this AD and paragraph (h)(2) has been added to this AD to 
provide the exception to allow P/N BACC30BS10K.

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 minor editorial changes, and 
any other 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-
SB530086-00 RB, Issue 001, dated October 18, 2024. This material 
specifies procedures for an X-ray fluorescence spectrometer inspection 
or a high frequency eddy current inspection of seat track splice 
fittings to determine the material and applicable on-condition actions. 
On-condition actions include replacing affected seat track splice 
fittings with new seat track splice fittings at affected locations. 
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 37 airplanes of U.S. 
registry. The FAA estimates the following costs to comply with this AD:

                                                 Estimated Costs
----------------------------------------------------------------------------------------------------------------
                                                                                     Cost per      Cost on U.S.
                Action                         Labor cost           Parts cost        product        operators
----------------------------------------------------------------------------------------------------------------
Inspection............................  16 work-hours x $85 per               $0          $1,360         $50,320
                                         hour = $1,360.
----------------------------------------------------------------------------------------------------------------

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

                                               On-Condition Costs
----------------------------------------------------------------------------------------------------------------
                Action                        Labor cost               Parts cost            Cost per product
----------------------------------------------------------------------------------------------------------------
Replacement..........................  Up to 20 work-hours x    Up to $4,140...........  Up to $5,840 (per
                                        $85 per hour = $1,700.                            location, up to 20
                                                                                          locations per
                                                                                          airplane).
----------------------------------------------------------------------------------------------------------------

    The FAA has included all known costs in its cost estimate. 
According to the manufacturer, however, some or all 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. 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:

2025-11-05 The Boeing Company: Amendment 39-23051; Docket No. FAA-
2025-0005; Project Identifier AD-2024-00646-T.

(a) Effective Date

    This airworthiness directive (AD) is effective July 8, 2025.

(b) Affected ADs

    None.

(c) Applicability

    This AD applies to The Boeing Company Model 787-8, 787-9, and 
787-10 airplanes, certificated in any category, as identified in 
Boeing Alert Requirements Bulletin B787-81205-SB530086-00 RB, Issue 
001, dated October 18, 2024.

[[Page 23427]]

(d) Subject

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

(e) Unsafe Condition

    This AD was prompted by reports of multiple supplier notices of 
escapement (NOEs) indicating that seat track splice fittings were 
possibly manufactured with an incorrect titanium alloy material. The 
unsafe condition, if not addressed, could result in failure of the 
seat track splice fittings, and could result in serious injury to 
seated occupants as a result of adverse effects on emergency egress 
and structural capability to react to emergency landing loads.

(f) Compliance

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

(g) Required Actions

    Except as specified by paragraph (h) of this AD: At the 
applicable times specified in the ``Compliance'' paragraph of Boeing 
Alert Requirements Bulletin B787-81205-SB530086-00 RB, Issue 001, 
dated October 18, 2024, do all applicable actions identified in, and 
in accordance with, the Accomplishment Instructions of Boeing Alert 
Requirements Bulletin B787-81205-SB530086-00 RB, Issue 001, dated 
October 18, 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-SB530086-00, Issue 001, dated October 18, 2024, which is 
referred to in Boeing Alert Requirements Bulletin B787-81205-
SB530086-00 RB, Issue 001, dated October 18, 2024.

(h) Exceptions to Requirements Bulletin Specifications

    (1) Where the Compliance Time column of the table in the 
``Compliance'' paragraph of Boeing Alert Requirements Bulletin B787-
81205-SB530086-00 RB, Issue 001, dated October 18, 2024, refers to 
the Issue 001 date of Requirements Bulletin B787-81205-SB530086-00 
RB, this AD requires using the effective date of this AD.
    (2) Where table 1 of task 17 and task 18 of Boeing Alert 
Requirements Bulletin B787-81205-SB530086-00 RB, Issue 001, dated 
October 18, 2024, specifies collars having a part number (P/N) of 
``BACC30BS10S'', this AD requires replacing that text with 
``BACC30BS10S or BACC30BS10K''.

(i) 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 
(j)(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.

(j) 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 (k)(3) 
of this AD.

(k) Material Incorporated by Reference

    (1) The Director of the Federal Register approved the 
incorporation by reference of the material listed in this paragraph 
under 5 U.S.C. 552(a) and 1 CFR part 51.
    (2) You must use this material as applicable to do the actions 
required by this AD, unless the AD specifies otherwise.
    (i) Boeing Alert Requirements Bulletin B787-81205-SB530086-00 
RB, Issue 001, dated October 18, 2024.
    (ii) [Reserved]
    (3) For the 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.
    (4) 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.
    (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 May 21, 2025.
Peter A. White,
Deputy Director, Integrated Certificate Management Division, Aircraft 
Certification Service.
[FR Doc. 2025-10061 Filed 6-2-25; 8:45 am]
BILLING CODE 4910-13-P

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