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FAA mandates increased inspections for Boeing 757 due to potential upper frame cracks

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FAA mandates increased inspections for Boeing 757 due to potential upper frame cracks
Policy
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The Federal Aviation Administration (FAA) has issued an airworthiness directive for specific Boeing 757 models following concerns over potential cracks in the upper frame. This decision comes after a crack growth analysis suggested that current inspection methods might not be sufficient to detect issues before a single frame failure occurs.

"The NPRM was prompted by a crack growth analysis, which indicated that current inspections are not adequate to detect cracks in certain sections of the upper frame at the frame splice between certain stringers before a single frame fails," stated the FAA.

The directive mandates inspections of existing repairs and repetitive checks of the upper frame at specific splices, with additional actions required if issues are found. A supplemental notice proposed revised inspection intervals for freighter-converted 757-200s by Aviation Partners Boeing (APB).

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Several stakeholders, including Boeing, FedEx, European Air Transport Leipzig (EATL), and United Airlines, provided feedback on the proposal. While Boeing supported the directive as is, FedEx requested shorter repeat intervals for its modified aircraft. The FAA did not accommodate this request due to insufficient supporting data from FedEx.

EATL and United Airlines expressed concerns about compliance times, with United noting potential burdens on operators. "United added that the FAA did not provide details regarding how it determined requiring a reduction in compliance by a factor of two," highlighting challenges without an approved service bulletin from APB.

EATL pointed out penalties related to winglet-equipped aircraft modified by APB's supplemental type certificate. The FAA maintained that reducing compliance time allows APB to complete evaluations on affected airplanes.

"The unsafe condition, if not addressed, could result in the inability of a principal structural element to sustain limit loads and could adversely affect the structural integrity of the airplane," explained the FAA.

Approximately 456 Boeing 757-200s are impacted by this directive. Inspections must occur every 3,000 or 6,000 flight cycles, potentially requiring up to 267 work hours per cycle according to FAA estimates. Delta Air Lines and United Airlines collectively operate 147 such aircraft with average fleet ages nearing three decades.

Organizations Included in this History
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