FAA Proposes Airworthiness Directive on B757 frames following discovery of Cracks

For some aircraft from The Boeing Company’s Model 757-200, -200CB, and -200PF series, the FAA is proposing to implement a new airworthiness directive (AD). This proposed AD was motivated by a crack growth analysis that revealed current inspections are insufficient to find cracks in certain upper frame sections at the frame splice between specific stringers before a single frame breaks.

This proposed AD would call for the following measures: an inspection or records review for existing repairs; repeated inspections for upper frame cracks at the frame splices between specific stringers in specific sections; and appropriate on-condition actions. To remedy the harmful issue with these products, the FAA is recommending this AD.

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According to a report received by the FAA, various frame sites on Boeing Model 737-300, -400, and -500 aircraft have had cracking in the frame splice doubler and may experience it in the upper frame at the upper frame splice between stringer S-13 and S-14. The unsafe situation on Boeing Model 737-300, -400, and -500 aircraft was addressed by the FAA in AD 2021-26-03, Amendment 29-21861 (87 FR 2534, January 18, 2022).

Boeing performed a cross-model review and crack growth analysis on its Model 757-200, -200CB, and -200PF series aircraft due to their similar designs.

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The FAA has also invited public comments and opinions on the proposed order, with a deadline of September 5 for submissions. It’s important to note that there have long been concerns about possible fuselage cracks in the Boeing 757. In 2018 and again in 2020, the FAA had issued directives that were specifically directed at this problem.