FAA addresses potential corrosion issue in Boeing 787 lavatories

To tackle the corrosion problem, the FAA has proposed requiring detailed inspections of the lavatory fitting assemblies and related components, as well as updating maintenance programs to watch for signs of corrosion or damage. "This proposed AD would also require revising the existing maintenance program to incorporate a detailed inspection of the lavatory vertical side forward fittings for corrosion or damage."

The estimated costs to comply with the directive include labor expenses of $1,275 per lavatory, with parts costing an additional $3,700 per lavatory. The total potential repair cost per aircraft could reach up to $29,850, while the overall cost for all affected US operators of 787s could amount to $4.7 million.

Additionally, updating the maintenance program would require around 90 working hours per operator, translating into an estimated cost of $7,650 per aircraft. The FAA clarified, "The FAA has received no definitive data on which to base the cost estimates for the on-condition repairs specified in this proposed AD."

The proposed directive relates to the Boeing Special Attention Requirements Bulletin B787-81205-SB250302-00 RB, issued on August 21, 2024. This document outlines the line numbers of affected aircraft and provides instructions on compliance and rectification timelines.

Data shows that American Airlines, Hawaiian Airlines, and United Airlines operate 138 Boeing 787s in the United States, facing potential impact from this directive.