FAA to Mandate Further Boeing 787 Structural Inspection
By Len Varley
The FAA will issue a new directive mandating inspections of the forward pressure bulkhead on Boeing 787 aircraft after reports of findings of “excessive gaps”
The Federal Aviation Administration (FAA) is issuing a new directive calling for further inspections of Boeing 787 Dreamliner aircraft. The new Airworthiness Directive (AD) centers on a critical structural component – the forward pressure bulkhead.
The bulkhead in question acts as a barrier between the pressurized cabin and the unpressurized area in the nose of the aircraft. It separates the forward area where the radome and radar equipment are located.
The proposed inspections arise from reports of manufacturing problems resulting in what was described as “excessive gaps”.
The most significant directive addresses the forward pressure bulkhead, a vital structural component located in the aircraft’s nose.
The FAA’s proposed airworthiness directive (AD) mandates inspections for all 787-8, 787-9, and 787-10 models. This action follows reports of manufacturing errors, specifically “excessive gaps” and improper installation.
These gaps pose a serious threat. They can trap foreign object debris (FOD), which can lead to corrosion and, critically, fatigue cracks.
Over time, these cracks can compromise the bulkhead’s ability to withstand the immense pressure differences experienced during flight. In a worst case scenario. the persistent cracking may potentially lead to catastrophic failure.
These latest directive adds to a growing list of concerns surrounding the 787. Recently, a LATAM Airlines 787-9 experienced a sudden and unexplained descent, prompting the FAA to investigate potential issues with flight deck seat switches.
In August 2024, the FAA mandated inspections of 787 seat track splice fittings. These fittings, which secure passenger seats to the aircraft’s floor, were under scrutiny due to concerns that some may have been manufactured with incorrect materials.
Using substandard materials can significantly weaken these fittings, compromising their ability to withstand the forces exerted during turbulence or emergency landings. This posed a direct risk to passenger safety, as seats could detach, leading to injuries.
What This Means for Passengers and Airlines
The latest structural inspections will likely lead to temporary disruptions for airlines operating 787s. Airlines will remove aircraft from service for inspections and any necessary repairs, potentially causing flight delays and cancellations.
It should be noted that the issuance of Airworthiness Directives for commercial aircraft is commonplace. AD’s will typically arise calling out additional inspections through the life of a commercial aircraft type.
What is notable in this instance is the string of issues previously identified with the Boeing widebody variant.
