Rule2025-22350
Airworthiness Directives; The Boeing Company Airplanes
Primary source
Metadata and text below are from the Federal Register, a public-domain U.S. government work. Always verify the official published version before relying on it for any legal matter.
Published
December 9, 2025
Effective
January 13, 2026
Issuing agencies
Transportation DepartmentFederal Aviation Administration
Abstract
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 of multiple supplier notices of escapement (NOEs) documenting pressure deck splice fittings that were possibly manufactured with an incorrect titanium alloy material. This AD requires an inspection of the attach fittings and upper splice fitting of the stub beam horizontal pressure deck (HPD) to determine the type of titanium alloy material and applicable on-condition actions. The FAA is issuing this AD to address the unsafe condition on these products.
Full Text
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<title>Federal Register, Volume 90 Issue 234 (Tuesday, December 9, 2025)</title>
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[Federal Register Volume 90, Number 234 (Tuesday, December 9, 2025)]
[Rules and Regulations]
[Pages 56974-56976]
From the Federal Register Online via the Government Publishing Office [<a href="http://www.gpo.gov">www.gpo.gov</a>]
[FR Doc No: 2025-22350]
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DEPARTMENT OF TRANSPORTATION
Federal Aviation Administration
14 CFR Part 39
[Docket No. FAA-2025-0749; Project Identifier AD-2025-00179-T;
Amendment 39-23189; AD 2025-23-06]
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 of multiple supplier notices of escapement
(NOEs) documenting pressure deck splice fittings that were possibly
manufactured with an incorrect titanium alloy material. This AD
requires an inspection of the attach fittings and upper splice fitting
of the stub beam horizontal pressure deck (HPD) to determine the type
of titanium alloy 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 January 13, 2026.
The Director of the Federal Register approved the incorporation by
reference of a certain publication listed in this AD as of January 13,
2026.
ADDRESSES:
AD Docket: You may examine the AD docket at <a href="http://regulations.gov">regulations.gov</a> under
Docket No. FAA-2025-0749; 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 the 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 <a href="http://myboeingfleet.com">myboeingfleet.com</a>.
<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 <a href="http://regulations.gov">regulations.gov</a> under
Docket No. FAA-2025-0749.
FOR FURTHER INFORMATION CONTACT: Joseph Hodgin, Aviation Safety
Engineer, FAA, 2200 South 216th St., Des Moines, WA 98198; phone: 206-
231-3962; email: <a href="/cdn-cgi/l/email-protection#0d67627e687d652367236562696a64634d6b6c6c236a627b"><span class="__cf_email__" data-cfemail="c2a8adb1a7b2aaeca8ecaaada6a5abac82a4a3a3eca5adb4">[email protected]</span></a>.
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 787-9 and 787-10 airplanes. The NPRM was published in the
Federal Register on May 14, 2025 (90 FR 20411). The NPRM was prompted
by reports of multiple supplier NOEs documenting pressure deck splice
fittings that were possibly manufactured with an incorrect titanium
alloy material. In the NPRM, the FAA proposed to require an inspection
of the attach fittings and upper splice fitting of the stub beam HPD to
determine the type of titanium alloy material, and applicable on-
condition actions. The FAA is issuing this AD to address pressure deck
splice fittings that were possibly manufactured with an incorrect
titanium alloy material, which could result in premature cracks in a
pressure deck splice fitting and lead to loss of residual strength of
the surrounding structure, resulting in the inability to sustain limit
load.
Discussion of Final Airworthiness Directive
Comments
The FAA received comments from United Airlines, who stated that it
had no objections to the proposed rule, and an anonymous commenter who
supported the NPRM without change.
The FAA received additional comments from American Airlines
(American) and Boeing. The following presents those comments and the
FAA's response.
Request To Clarify Inspection Instructions
American requested that the FAA revise the proposed AD to state
that either an X-ray fluorescent (XRF) or high frequency eddy current
(HFEC) inspection method is acceptable for compliance with the proposed
AD. The commenter expressed concern that paragraph (g) of the proposed
AD specifies doing all applicable actions identified in, and in
accordance with, the Accomplishment Instructions of Boeing Alert
Requirements Bulletin
[[Page 56975]]
B787-81205-SB530091-00 RB, Issue 001, dated February 7, 2025, but the
inspection instructions in the requirements bulletin do not clearly
state that doing an HFEC inspection to determine the type of titanium
alloy material negates the need for an XRF inspection (for example, see
task 5). The commenter stated it cannot accomplish the XRF inspection
because the equipment is unavailable.
The FAA disagrees with the request. Tables 1 through 5 in the
Accomplishment Instructions of the requirements bulletin specify to
``Do a High Frequency Eddy-Current (HFEC) inspection or handheld X-Ray
Fluorescence (XRF) Spectrometer inspection of the affected Stub Beam
HPD Attach fitting(s) and Upper Splice fitting to determine titanium
alloy material.'' In addition, footnote 2 of the corresponding Method
of Compliance task tables states: ``As an option, do a High Frequency
Eddy-Current (HFEC) inspection of the stub beam HPD attach fitting to
determine the material in accordance with 787 NDT Manual Part 6, 51-00-
13.'' Footnote 2 denotes that the HFEC inspection is an alternative to
the XRF inspection specified in footnote 1. Therefore, operators may
accomplish either an HFEC or XFR inspection to comply with the AD
requirement to determine the type of titanium alloy material. No change
to the AD is necessary in this regard.
Request To Revise the Number of Affected Airplanes
Boeing requested that the FAA revise the estimated number of
affected airplanes of U.S. registry from 11 to 13 in the Costs of
Compliance paragraph of the proposed AD and adjust the costs
accordingly. Boeing noted that Boeing Alert Requirements Bulletin B787-
81205-SB530091-00 RB, Issue 001, dated February 7, 2025, includes 13
airplanes of U.S. registry. Boeing explained that the two additional
airplanes are currently operated by foreign operators but remain on the
U.S. registry.
The FAA agrees with the request. The FAA has revised the Costs of
Compliance section of this AD accordingly.
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-
SB530091-00 RB, Issue 001, dated February 7, 2025. This material
specifies procedures for an HFEC inspection or handheld XRF
spectrometer inspection of the affected stub beam HPD attach fittings
and upper splice fitting (if applicable to the group) to determine the
titanium alloy material, and applicable related investigative and
corrective actions. Related investigative actions include an open hole
HFEC inspection for cracking of the fastener hole locations common to
the interfacing structure of affected stub beam HPD attach fittings and
affected upper splice fittings. Corrective actions include repairing
cracks and obtaining instructions for installation of new fittings,
replacing all affected stub beam HPD attach fittings with new stub beam
HPD attach fittings made of Ti-6Al-4V alloy material, and replacing all
affected upper splice fittings (if applicable to the group) with new
upper splice fittings made of Ti-6Al-4V alloy 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 13 airplanes of U.S.
registry. The FAA estimates the following costs to comply with this AD:
Estimated Costs
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Action Labor cost Parts cost Cost per product Cost on U.S. operators
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Inspection.................... Up to 12 work- $0 Up to $1,020........... Up to $13,260.
hours x $85 per
hour = $1,020.
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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 these
replacements:
On-Condition Costs
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Action Labor cost Parts cost Cost per product
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Open hole HFEC inspection........ Up to 3 work-hours x $0......................... Up to $255.
$85 per hour = $255.
Replacement...................... 52 work-hours x $85 Up to $17,570.............. Up to $21,990.
per hour = $4,420.
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The FAA has received no definitive data on which to base the cost
estimates for certain installation instructions or repairs specified in
this AD.
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
[[Page 56976]]
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:
2025-23-06 The Boeing Company: Amendment 39-23189; Docket No. FAA-
2025-0749; Project Identifier AD-2025-00179-T.
(a) Effective Date
This airworthiness directive (AD) is effective January 13, 2026.
(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-SB530091-00 RB, Issue 001,
dated February 7, 2025.
(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 documenting pressure deck splice fittings that were
possibly manufactured with an incorrect titanium alloy material. The
unsafe condition, if not addressed, could result in premature cracks
in a pressure deck splice fitting and lead to loss of residual
strength of the surrounding structure, resulting in the inability to
sustain limit load.
(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-SB530091-00 RB, Issue 001,
dated February 7, 2025, do all applicable actions identified in, and
in accordance with, the Accomplishment Instructions of Boeing Alert
Requirements Bulletin B787-81205-SB530091-00 RB, Issue 001, dated
February 7, 2025.
Note 1 to paragraph (g): Guidance for accomplishing the actions
required by this AD can be found in Boeing Alert Service Bulletin
B787-81205-SB530091-00, Issue 001, dated February 7, 2025, which is
referred to in Boeing Alert Requirements Bulletin B787-81205-
SB530091-00 RB, Issue 001, dated February 7, 2025.
(h) Exceptions to Requirements Bulletin Specifications
(1) Where the Compliance Time columns of the tables in the
``Compliance'' paragraph of Boeing Alert Requirements Bulletin B787-
81205-SB530091-00 RB, Issue 001, dated February 7, 2025, refer to
the Issue 001 date of Requirements Bulletin B787-81205-SB530091 RB,
this AD requires using the effective date of this AD.
(2) Where Boeing Alert Requirements Bulletin B787-81205-
SB530091-00 RB, Issue 001, dated February 7, 2025, specifies
contacting Boeing for repair instructions and certain installation
instructions: This AD requires doing the repair or installation
using a method approved in accordance with the procedures specified
in paragraph (i) of this AD.
(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 Continued Operational
Safety Branch, send it to the attention of the person identified in
paragraph (j)(1) of this AD. Information may be emailed to:
<a href="/cdn-cgi/l/email-protection#4d0c00020e0d2b2c2c632a223b"><span class="__cf_email__" data-cfemail="66272b29252600070748010910">[email protected]</span></a>. Before using any approved AMOC, notify your
appropriate principal inspector, or lacking a principal inspector,
the manager of the responsible Flight Standards Office.
(2) 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) Additional 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: <a href="/cdn-cgi/l/email-protection#81ebeef2e4f1e9afebafe9eee5e6e8efc1e7e0e0afe6eef7"><span class="__cf_email__" data-cfemail="771d180412071f591d591f1813101e193711161659101801">[email protected]</span></a>.
(2) Material identified in this AD that is not incorporated by
reference is available at the address specified in paragraph (k)(3)
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-SB530091-00
RB, Issue 001, dated February 7, 2025.
(ii) [Reserved]
(3) For the 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 <a href="http://myboeingfleet.com">myboeingfleet.com</a>.
(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 <a href="http://www.archives.gov/federal-register/cfr/ibr-locations">www.archives.gov/federal-register/cfr/ibr-locations</a>, or email <a href="/cdn-cgi/l/email-protection#5b3d29753235282b3e382f3234351b353a293a753c342d"><span class="__cf_email__" data-cfemail="1375613d7a7d60637670677a7c7d537d7261723d747c65">[email protected]</span></a>.
Issued on November 7, 2025.
Peter A. White,
Deputy Director, Integrated Certificate Management Division, Aircraft
Certification Service.
[FR Doc. 2025-22350 Filed 12-8-25; 8:45 am]
BILLING CODE 4910-13-P
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