Federal Register #2026-22318

FAA directive requiring fuel-tank sealant inspections on Boeing 787 aircraft

The FAA issued a safety directive requiring sealant inspections on certain Boeing 787 aircraft. - Government buyer: U.S. Department of Transportation, Federal Aviation Administration (FAA). - OEM: Boeing; the directive references Boeing Alert Requirements Bulletin B787-81205-SB570053-00 RB. - Affected aircraft: Certain Boeing 787-8, 787-9, and 787-10 airplanes; an estimated 60 U.S.-registered aircraft are affected. These aircraft are subject to the directive, not being procured. - Required work: Detailed inspections and adhesion tests of specified sealant installations in the left, right, and center wing side-of-body areas, plus applicable on-condition actions and repairs. Estimated labor is 34 work-hours per airplane. - Notable requirement and risk: Sealant defects could create an ignition source in a fuel tank and lead to an explosion during a lightning strike. - Estimated cost: The directive estimates inspection costs of $2,890 per airplane, or approximately $173,400 for 60 aircraft. This is a regulatory cost estimate, not a contract value.

Description

The FAA is adopting an airworthiness directive for certain Boeing 787-8, 787-9, and 787-10 airplanes. It requires detailed inspections of specified sealant installations in wing side-of-body areas, adhesion testing, and applicable repairs or other on-condition actions. The directive addresses sealant defects that could create an ignition source in the fuel tank and risk an explosion during a lightning strike. It is effective December 7, 2026.

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