Rule2025-22363
Airworthiness Directives; The Boeing Company Airplanes
Primary source
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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 787-8, 787-9, and 787-10 airplanes. This AD was prompted by reports of multiple nonconformances, including excessive gaps and pull-up, in the forward pressure bulkhead. This AD requires an internal and external detailed inspection (DET) of the forward pressure bulkhead (FPB) for any damage and performing 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 56977-56980]
From the Federal Register Online via the Government Publishing Office [<a href="http://www.gpo.gov">www.gpo.gov</a>]
[FR Doc No: 2025-22363]
[[Page 56977]]
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DEPARTMENT OF TRANSPORTATION
Federal Aviation Administration
14 CFR Part 39
[Docket No. FAA-2025-0338; Project Identifier AD-2024-00641-T;
Amendment 39-23188; AD 2025-23-05]
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 nonconformances, including
excessive gaps and pull-up, in the forward pressure bulkhead. This AD
requires an internal and external detailed inspection (DET) of the
forward pressure bulkhead (FPB) for any damage and performing
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-2025-0338; 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 <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-2025-0338.
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#147e7b6771647c3a7e3a7c7b70737d7a547275753a737b62"><span class="__cf_email__" data-cfemail="553f3a2630253d7b3f7b3d3a31323c3b153334347b323a23">[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 787-8, 787-9, and 787-10 airplanes. The NPRM was
published in the Federal Register on March 14, 2025 (90 FR 12115). The
NPRM was prompted by reports of multiple nonconformances, including
excessive gaps and pull-up, in the forward pressure bulkhead. In the
NPRM, the FAA proposed to require an internal and external DET of the
FPB for any damage and performing applicable on-condition actions. The
FAA is issuing this AD to address fatigue cracks that can develop prior
to baseline structural inspection thresholds. The unsafe condition, if
not addressed, could result in undetected fatigue cracks that can grow
to weaken the primary structure where it cannot sustain limit load,
which could adversely affect the structural integrity of the airplane.
Discussion of Final Airworthiness Directive
Comments
The FAA received comments from Boeing, ProTech Aero Services
Limited (ProTech), two individuals, and two anonymous commenters who
supported the NPRM without change.
The FAA also received comments from Qantas Airlines (Qantas) and
United Airlines (UAL), who supported the NPRM but also requested
changes as discussed below.
The FAA received additional comments from three other commenters,
including the Foundation for Aviation Safety, an individual, and an
anonymous commenter. The following presents the comments received on
the NPRM and the FAA's response to each comment.
Request To Correct a Typographical Error
UAL and Qantas requested that the FAA revise paragraph (d) of the
proposed AD to read ``Air Transport Association (ATA) of America Code
53, Fuselage.'' Qantas commented that ATA 41 is a minor error in
paragraph (d) in the proposed AD. Both commenters stated that the ATA
code should be 53.
The FAA agrees to correct the typographical error. The FAA has
revised paragraph (d) of this AD accordingly.
Request To Revise Work Instructions
UAL requested that the FAA revise the Work Instructions of Boeing
Alert Service Bulletin B787-81205-SB530093-00, Issue 001, dated October
5, 2024, to remove step (b) of Part 1 from the service bulletin or make
it optional. UAL commented that step (b) of Part 1 instructs to remove
the insulation blanket from the nose radome area and stated that no
insulation blanket is present per Boeing Illustrated Parts Data (IPD)
53-13-01-01.
The FAA disagrees with UAL's request. Step (b) of Part 1 of Boeing
Alert Service Bulletin B787-81205-SB530093-00, Issue 001, dated October
5, 2024, is not a Required for Compliance (RC) step, therefore it is
optional to perform. The FAA has not changed this AD in this regard.
Request for Reporting to the FAA
An anonymous commenter requested that all inspection reports be
submitted to the FAA in anonymized form to facilitate broader data
collection and trend analysis.
The FAA disagrees with the commenter's request. The actions
required by this AD address the identified unsafe condition. The FAA
notes that if any cracking is found as the result of any inspections,
then it must be reported in accordance with 14 CFR 21.3 The FAA has not
changed this AD in this regard.
Request To Expand Inspections and Mandate Re-Inspection
An anonymous commenter requested that the FAA expand the
inspections to include adjacent fuselage structures potentially
affected by assembly errors to prevent undetected cascading structural
failures. The commenter also requested that the FAA mandate periodic
re-inspection schedules beyond the initial compliance for affected
aircraft.
The FAA disagrees with the commenter's request. The actions
required by this AD address the identified unsafe condition. The FAA
notes that for any repaired area, post-repair inspections are required
by maintenance and operational rules; therefore, it is not necessary to
mandate them in this AD. However, if additional data are presented that
would justify expanding the inspection area or mandating repetitive
inspections, the FAA might consider further rulemaking
[[Page 56978]]
on this issue. The FAA has not revised this AD in this regard.
Request To Address Costs of Compliance
An anonymous commenter requested that, given that on-condition
repairs may not be fully covered under warranty, the FAA provide more
detailed cost ranges to better inform small operators and promote
economic equity.
The FAA acknowledges the commenter's concern. For this AD, the
repair costs will vary depending on what damage is found, so the FAA
has no way of estimating them. Although this AD imposes certain
operational costs (inspections) on operators, all operators have an
obligation to ensure that their airplanes are in airworthy condition.
The FAA has not changed the AD in this regard.
Feedback on Training, Environmental Impact, Supply Chain, Worker
Safety, Diversity, and New Technology
An anonymous commenter provided feedback on a range of topics,
including workforce training, environmental impact, supply chain
oversight, worker safety reporting, diversity and equity
considerations, and new technologies.
The FAA acknowledges the commenter's feedback; however, these
matters are outside the scope of this AD, and the commenter did not
request any specific revisions to the proposed AD. The FAA has not
changed this AD in this regard.
Request To Address Concerns With Forward Pressure Bulkheads
An individual expressed concern that the proposed AD is inadequate
and does not adequately address the underlying issues with non-
compliant forward pressure bulkheads. The commenter stated there are
some problems with the forward pressure bulkhead and commented on
Boeing Alert Requirements Bulletin B787-81205-SB530093-00 RB, Issue
001, dated October 5, 2024. The commenter urged that the FAA further
investigate pressure bulkhead safety risks for the safety of the
public.
The FAA acknowledges the commenter's concern. The FAA investigated
and verified with Boeing that the concerns regarding problems with
forward pressure bulkheads were appropriately addressed in the analysis
conducted during the safety investigation. The FAA has determined that
an unsafe condition exists related to the forward pressure bulkhead, as
specified in paragraph (e) of this AD, and has worked with Boeing to
ensure all known non-conformances were considered during the evaluation
of this safety issue.
Comments on Mandated Service Information
The same individual also provided comments on Boeing Alert
Requirements Bulletin B787-81205-SB530093-00 RB, Issue 001, dated
October 5, 2024, that relate to accomplishing the required actions. The
following specifies those comments that implicate a request for
changes, and the FAA's responses.
The commenter stated that the detailed inspection is inadequate
because sealant covers the inspection zone and stated that a non-
destructive inspection (NDI) for cracking should instead be done.
The FAA notes that only the fastener is encased in sealant and that
it is not necessary to see the fastener to do the detailed inspection,
which looks for cracks that will extend beyond the fastener sealant and
cracks near the chord radius. An NDI is not required to detect such
cracking. The detailed inspections required by this AD detect any early
cracking resulting from identified non-conformances. However, if
additional data are presented that would justify requiring NDIs in the
subject area, the FAA might consider further rulemaking.
The commenter noted that for torque values, the structural repair
manual (SRM) should be followed on interference fit.
The FAA notes that the commenter referred to ``torque values'' in a
standard note in the General Information paragraph of the
Accomplishment Instructions of Boeing Alert Requirements Bulletin B787-
81205-SB530093-00 RB, Issue 001, dated October 5, 2024. The removal and
installation of fasteners common to the forward pressure bulkhead is
not an action specified in the requirements bulletin. If, however, any
damage is detected during an inspection specified in Boeing Alert
Requirements Bulletin B787-81205-SB530093-00 RB, Issue 001, dated
October 5, 2024, the operator is instructed to contact Boeing for
repair instructions and do the repair. The repair instructions would
include fastener installation requirements such as torquing values and
appropriate hole fit requirements.
The commenter suggested ``a remove and replace'' in a standard note
in the General Information paragraph of the Accomplishment Instructions
of Boeing Alert Requirements Bulletin B787-81205-SB530093-00 RB, Issue
001, dated October 5, 2024.
The FAA notes that this is a standard note for removing parts for
access. No removal of structure is necessary to perform the required
detailed inspection. If, however, any damage is detected during an
inspection specified in Boeing Alert Requirements Bulletin B787-81205-
SB530093-00 RB, Issue 001, dated October 5, 2024, the operator is
instructed to contact Boeing for repair instructions and do the repair.
The repair instructions would include any applicable removal and
replacement requirements.
The FAA has not changed this AD in regard to these comments.
Support for Previous Commenter
The Foundation for Aviation Safety expressed support for the points
made by the individual who requested changes to the mandated service
instructions. They also expressed concern for the manufacturing of
Boeing airplanes, and the actions government agencies are taking to
mitigate what it described as chronic manufacturing problems.
The FAA addressed the referenced individual's comments above.
Otherwise, the Foundation for Aviation Safety did not request any
change to the AD.
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-
SB530093-00 RB, Issue 001, dated October 5, 2024. This material
specifies procedures for an internal DET of the FPB attach angle and
splice chords as well as an external DET of the FPB dome web and Y-
chord for any damage and applicable on-condition actions including
repair. 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 135 airplanes of U.S.
registry.
[[Page 56979]]
The FAA estimates the following costs to comply with this AD:
Estimated Costs
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Cost per Cost on U.S.
Action Labor cost Parts cost product operators
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Inspections........................... 10 work-hours x $85 per $0 $850 $114,750
hour = $850.
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The FAA has received no definitive data on which to base the cost
estimates for the on-condition 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 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:
2025-23-05 The Boeing Company: Amendment 39-23188; Docket No. FAA-
2025-0338; Project Identifier AD-2024-00641-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 787-8, 787-9, and
787-10 airplanes, certificated in any category, as identified in
Boeing Alert Requirements Bulletin B787-81205-SB530093-00 RB, Issue
001, dated October 5, 2024.
(d) Subject
Air Transport Association (ATA) of America Code 53, Fuselage.
(e) Unsafe Condition
This AD was prompted by reports of multiple nonconformances,
including excessive gaps and pull-up, in the forward pressure
bulkhead. The FAA is issuing this AD to address fatigue cracks that
can develop prior to baseline structural inspection thresholds. The
unsafe condition, if not addressed, could result in undetected
fatigue cracks that can grow to weaken the primary structure where
it cannot sustain limit load, which could adversely affect the
structural integrity of the airplane.
(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-SB530093-00 RB, Issue 001,
dated October 5, 2024, do all applicable actions identified in, and
in accordance with, the Accomplishment Instructions of Boeing Alert
Requirements Bulletin B787-81205-SB530093-00 RB, Issue 001, dated
October 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-SB530093-00, Issue 001, dated October 5, 2024, which is
referred to in Boeing Alert Requirements Bulletin B787-81205-
SB530093-00 RB, Issue 001, dated October 5, 2024.
(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-SB530093-00 RB, Issue 001, dated October 5, 2024, refer to the
Issue 001 date of Requirements Bulletin B787-81205-SB530093-00 RB,
this AD requires using the effective date of this AD.
(2) Where Boeing Alert Requirements Bulletin B787-81205-
SB530093-00 RB, Issue 001, dated October 5, 2024, specifies
contacting Boeing for repair instructions, this AD requires doing
the repair 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 certification office,
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#793834363a391f1818571e160f"><span class="__cf_email__" data-cfemail="e8a9a5a7aba88e8989c68f879e">[email protected]</span></a>.
(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
[[Page 56980]]
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: <a href="/cdn-cgi/l/email-protection#85efeaf6e0f5edabefabedeae1e2ecebc5e3e4e4abe2eaf3"><span class="__cf_email__" data-cfemail="caa0a5b9afbaa2e4a0e4a2a5aeada3a48aacababe4ada5bc">[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-SB530093-00
RB, Issue 001, dated October 5, 2024.
(ii) [Reserved]
(3) 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 <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#badcc894d3d4c9cadfd9ced3d5d4fad4dbc8db94ddd5cc"><span class="__cf_email__" data-cfemail="7513075b1c1b06051016011c1a1b351b1407145b121a03">[email protected]</span></a>.
Issued on December 5, 2025.
Peter A. White,
Deputy Director, Integrated Certificate Management Division, Aircraft
Certification Service.
[FR Doc. 2025-22363 Filed 12-8-25; 8:45 am]
BILLING CODE 4910-13-P
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