[Federal Register Volume 90, Number 105 (Tuesday, June 3, 2025)]
[Rules and Regulations]
[Pages 23429-23432]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 2025-10060]
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DEPARTMENT OF TRANSPORTATION
Federal Aviation Administration
14 CFR Part 39
[Docket No. FAA-2025-0012; Project Identifier AD-2024-00219-T;
Amendment 39-23047; AD 2025-11-01]
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 757-200, -200CB, and -300 series
airplanes. This AD was prompted by a report of cracking found in new
locations at a certain body station (STA) during frame segment
replacement repairs, including in the web at the K-hole between certain
stringers, in the outer chord above the
[[Page 23430]]
lower hinge intercostal, and in the inner chord and web between certain
stringers. This AD requires an inspection or records check for the
presence of approved or local repairs, repetitive eddy current
inspections for cracking, 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 certain publications 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-2025-0012; 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:
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.
For the Aviation Partners Boeing material identified in
this AD, contact Aviation Partners Boeing, 555 Andover Park West, Suite
200, Tukwila, WA 98188; telephone 206-830-7699; fax 206-767-0535; email
partners.com">leng@aviationpartners.com; website aviationpartnersboeing.com.
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-2025-0012.
FOR FURTHER INFORMATION CONTACT: Wayne Ha, Aviation Safety Engineer,
FAA, 2200 South 216th St., Des Moines, WA 98198; phone: 562-627-5238;
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 757-200, -200CB, and -300 series airplanes. The NPRM was
published in the Federal Register on January 31, 2025 (90 FR 8690). The
NPRM was prompted by a report of cracking found in new locations at STA
1640 during frame segment replacement repairs, including in the web at
the K-hole between stringers S-9 and S-10, in the outer chord above the
lower hinge intercostal, and in the inner chord and web between
stringers S-10 and S-19. In the NPRM, the FAA proposed to require an
inspection or records check for the presence of approved or local
repairs, repetitive eddy current inspections for cracking, and
applicable on-condition actions. The FAA is issuing this AD to address
undetected cracks in the fuselage frame at STA 1640, which could affect
a principal structural element's ability to sustain limit load. The
unsafe condition, if not addressed, could result in reduced structural
integrity of the airplane.
Discussion of Final Airworthiness Directive
Comments
The FAA received comments from United Airlines and four individuals
who supported the NPRM without change.
The FAA received additional comments from Aviation Partners Boeing
(APB), FedEx, and an anonymous commenter. The following presents the
comments received on the NPRM and the FAA's response to each comment.
Request To Revise Address for APB
APB requested a revision to the mailing address identified in
paragraph (k)(4) of the proposed AD. APB noted that the address
identified in that paragraph is not current and provided an address
that is current with the reissuance of supplemental type certificate
(STC) ST01518SE, dated April 20, 2024.
The FAA agrees to revise the address and has revised the ADDRESSES
section and paragraph (k)(4) of this AD with the current address.
Request To Add an Exception To Address Frame Segment Replacement
Repairs
FedEx requested an exception be added to paragraph (h) of the
proposed AD to address frame segment replacement repairs that meet
certain criteria and are FAA-approved in accordance with FAA Form 8100-
9 or 8110-3. FedEx reasoned that if existing frame segment replacement
repairs are approved as alternative methods of compliance (AMOCs) to
other ADs, then those AMOCs should be extended to this proposed AD.
FedEx stated that if the FAA does not include the suggested exception,
then operators would need to apply for AMOCs for existing frame segment
replacement repairs.
The FAA disagrees with the request to add this exception to
paragraph (h) of this AD. The frame segment replacement repairs
specified by FedEx are not identified in the Boeing Alerts Requirements
Bulletin 757-53A0123 RB, dated March 13, 2024, and would need to be
reviewed through the AMOC process specified in paragraph (i) of this
AD. Although existing frame segment replacement repairs might be
approved as AMOCs to other ADs, the repairs have not been reviewed to
determine if they also address the unsafe condition identified in this
AD. No change has been made to this AD in this regard.
Request To Explain Scope of Proposed AD
An individual commenter asked why the proposed AD was not already
in effect and stated that the proposed rule should apply to every
airline company.
The FAA agrees to clarify. In accordance with 14 CFR 39.5, the FAA
issues an AD when an unsafe condition exists or is likely to develop in
other products of the same type design. An AD will apply to products
(aircraft, aircraft engines, propellers, and appliances) that either
has or is likely to develop the unsafe condition. 14 CFR 39.7 specifies
that once an AD is issued, no person may operate a product to which the
AD applies except in accordance with the requirements of that AD. This
AD was not previously issued because this safety issue was only
recently found in service. Once the safety issue was reported, the FAA
initiated the rulemaking process after performing an analysis of the
findings and determining that an unsafe condition exists. The analysis
led to the determination that this AD is applicable only to Model 757-
200, -200CB, and -300 series airplanes. Thus, only operators of these
affected models are required to comply with this 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.
[[Page 23431]]
Material Incorporated by Reference Under 1 CFR Part 51
The FAA reviewed Boeing Alert Requirements Bulletin 757-53A0123 RB,
dated March 13, 2024. This material specifies procedures for an
inspection or records check for the presence of approved repairs at STA
1640 frame between stringers S-9 and S-19, left and right sides, or
local repairs at specified locations at STA 1640; repetitive eddy
current inspections for cracking of the STA 1640 frame inner chord, web
and outer chord at specified locations; and applicable on-condition
actions. On-condition actions include contacting Boeing for repair.
The FAA also reviewed Aviation Partners Boeing Alert Service
Bulletin AP757-53-006, dated May 7, 2024. This material specifies
procedures for an inspection or records check for the presence of
approved repairs at STA 1640 frame between stringers S-9 and S-19, left
and right sides, or local repairs at specified locations at STA 1640,
repetitive eddy current inspections for cracking of the STA 1640 frame
inner chord, web and outer chord at specified locations, and applicable
on-condition actions. On-condition actions include contacting Boeing
for repair.
These documents are distinct since they apply to different airplane
configurations. 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 481 airplanes of U.S.
registry. The FAA estimates the following costs to comply with this AD:
Estimated Costs
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Cost on U.S.
Action Labor cost Parts cost Cost per product operators
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Inspection for presence of 69 work-hours x None.............. $5,865............ $2,821,065.
repairs. $85 per hour =
$5,865.
Eddy current inspections........ Up to 74 work- None.............. Up to $6,290 per Up to $3,025,490
hours x $85 per inspection cycle. per inspection
hour = $6,290 per cycle.
inspection cycle.
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The FAA has received no definitive data on which to base the cost
estimates for the repairs specified in this AD.
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:
2025-11-01 The Boeing Company: Amendment 39-23047; Docket No. FAA-
2025-0012; Project Identifier AD-2024-00219-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 757-200, -200CB, and
-300 series airplanes, certificated in any category, as identified
in Boeing Alert Requirements Bulletin 757-53A0123 RB, dated March
13, 2024.
(d) Subject
Air Transport Association (ATA) of America Code 53, Fuselage.
(e) Unsafe Condition
This AD was prompted by a report of cracking found in new
locations at body station (STA) 1640 during frame segment
replacement repairs, including in the web at the K-hole between
stringers S-9 and S-10, in the outer chord above the lower hinge
intercostal, and in the inner chord and web between stringers S-10
and S-19. The FAA is issuing this AD to address undetected cracks in
the fuselage frame at STA 1640, which could affect a principal
structural element's ability to sustain limit load. The unsafe
condition, if not addressed, could result in reduced structural
integrity of the airplane.
(f) Compliance
Comply with this AD within the compliance times specified,
unless already done.
(g) Required Actions
(1) For all airplanes except those identified in paragraph
(g)(2) of this AD: Except as specified by paragraph (h) of this AD:
At the applicable times specified in the ``Compliance'' paragraph of
Boeing Alert Requirements Bulletin 757-53A0123 RB, dated March 13,
2024, do all applicable actions identified in, and in accordance
with, the Accomplishment Instructions of Boeing Alert Requirements
Bulletin 757-53A0123 RB, dated March 13, 2024.
[[Page 23432]]
Note 1 to paragraph (g)(1): Guidance for accomplishing the
actions required by this AD can be found in Boeing Alert Service
Bulletin 757-53A0123, dated March 13, 2024, which is referred to in
Boeing Alert Requirements Bulletin 757-53A0123 RB, dated March 13,
2024.
(2) For airplanes identified in Aviation Partners Boeing Alert
Service Bulletin AP757-53-006, dated May 7, 2024: Except as
specified in paragraph (h) of this AD, at the applicable times
specified in paragraph 1.E., ``Compliance,'' of Aviation Partners
Boeing Alert Service Bulletin AP757-53-006, dated May 7, 2024, do
all applicable actions identified in, and in accordance with, the
Accomplishment Instructions of Boeing Alert Requirements Bulletin
757-53A0123 RB, dated March 13, 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 757-
53A0123 RB, dated March 13, 2024, refer to the original issue date
of Requirements Bulletin 757-53A0123 RB, this AD requires using the
effective date of this AD.
(2) Where Boeing Alert Requirements Bulletin 757-53A0123 RB,
dated March 13, 2024, specifies contacting Boeing for repair
instructions or for alternative inspections: This AD requires doing
the repair, or doing the alternative inspections and applicable on-
condition actions, using a method approved in accordance with the
procedures specified in paragraph (i) of this AD.
(3) Where the Compliance Time columns of the tables in the
``Compliance'' paragraph of Aviation Partners Boeing Alert Service
Bulletin AP757-53-006, dated May 7, 2024, refer to the original
issue date of Requirements Bulletin 757-53A0123 RB, this AD requires
using the effective date of this AD.
(4) Where Aviation Partners Boeing Alert Service Bulletin AP757-
53-006, dated May 7, 2024, specifies contacting Boeing for repair
instructions or for alternative inspections: This AD requires doing
the repair, or doing the alternative inspections and applicable on-
condition actions, 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: [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 Wayne Ha,
Aviation Safety Engineer, FAA, 2200 South 216th St., Des Moines, WA
98198; phone: 562-627-5238; 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 757-53A0123 RB, dated
March 13, 2024.
(ii) Aviation Partners Boeing Alert Service Bulletin AP757-53-
006, dated May 7, 2024.
(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 myboeingfleet.com.
(4) For the Aviation Partners Boeing material identified in this
AD, contact Aviation Partners Boeing, 555 Andover Park West, Suite
200, Tukwila, WA 98188; telephone 206-830-7699; fax 206-767-0535;
email partners.com">leng@aviationpartners.com; website
aviationpartnersboeing.com.
(5) 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.
(6) 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 19, 2025.
Peter A. White,
Deputy Director, Integrated Certificate Management Division, Aircraft
Certification Service.
[FR Doc. 2025-10060 Filed 6-2-25; 8:45 am]
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