The FAA mandates urgent inspections and repairs for Boeing 757-200 freighters due to fatigue cracks, primarily affecting DHL and SF Airlines.
The Federal Aviation Administration (FAA) has issued an airworthiness directive for Boeing 757-200 aircraft converted from passenger to cargo configurations by Precision Aircraft Solutions. This order comes after the discovery of fatigue cracks in the lavatory service panels of these freighters, significantly impacting DHL Express and China-based SF Airlines, according to FreightWaves.
The FAA directive, issued last month, requires immediate inspections within three months and necessary repairs and replacements for the affected areas. The order applies to 13 US-registered aircraft but affects a total of 120 planes worldwide. Precision Aircraft Solutions has provided a service bulletin for addressing the issue, but the FAA directive mandates compliance within two years to prevent significant in-flight depressurization and structural integrity problems.
SF Airlines, the in-house airline of SF Express, operates 38 of these freighters, while DHL Express has 32, including some managed by partner Blue Dart Aviation in India. Precision has completed over 150 conversions globally, including for airlines like Asia Pacific Airlines, Cargojet, Air Transport International, Cainiao, Air China Cargo, China Postal Airlines, and YTO Cargo Airlines.
Pam Duque, a spokeswoman for DHL, stated that they are working closely with Precision to ensure all inspections and repairs are completed within the required timeframe, minimizing any additional costs or downtime.
The FAA’s directive highlights the critical issue of fatigue cracking around the lavatory service panels, which can lead to severe safety risks if not addressed. Operators are required to conduct repetitive inspections, reinforce structures, and repair or replace any cracked components within 2,000 flight cycles after the initial inspection.
The affected 757–200 freighter fleet, averaging over 27 years in age, underscores the complexity of converting used passenger jets into cargo carriers. This process involves extensive modifications, including gutting interiors, installing cargo doors, and reinforcing floors and walls to handle heavy loads.
Despite these challenges, the fleet has demonstrated a robust safety record since 2005, accumulating over 1.4 million flight hours and 750,000 flight cycles. Precision Aircraft Solutions assures that it will collaborate with each operator to ensure timely compliance with the FAA directive while minimizing operational disruptions.
