Boeing 787 Lavatory May Break Free in Flight Injuring Crew and Pax: FAA

WASHINGTON- The Federal Aviation Administration (FAA) has proposed a new Airworthiness Directive (AD) affecting Boeing 787-8, 787-9, and 787-10 aircraft. This action comes after reports of corrosion on lower fitting assemblies of certain lavatories.

The corrosion stems from the galvanic interaction between aluminum and carbon fiber in the wet environment of the lavatory. If left unaddressed, this corrosion could cause lavatories to break free during high g-force events, as per the FAA report.

Photo- Boeing

Boeing 787 Lavatory Issues

Boeing 787 aircraft are facing a safety concern with their lavatories, according to a recent FAA proposal. The agency has identified corrosion problems on lower fitting assemblies of Jamco family 95/96 lavatories caused by galvanic interaction between aluminum and carbon fiber components in the wet lavatory environment.

This corrosion could cause lavatories to break free during high g-force events, potentially injuring passengers and crew or blocking emergency exits.

The proposed Airworthiness Directive (AD) would require airlines to inspect the affected components for corrosion, record findings, make necessary repairs, and update maintenance programs to include regular inspections.

The directive would affect approximately 159 U.S.-registered Boeing 787-8, 787-9, and 787-10 airplanes.

Photo- Heute; Wikimedia Commons

Required Inspections and Maintenance

The directive would require airlines to:

• Perform detailed inspections of the eight lower fitting assemblies and centerline partition threshold of Jamco family 95/96 lavatories
• Record findings on modification record placards
• Complete necessary repairs if corrosion is found
• Update maintenance programs to include regular inspections of lavatory vertical side forward fittings

Estimated Costs

Implementation costs are estimated at $7,650 per operator, based on approximately 90 work hours at $85 per hour. The parts manufacturer may cover some costs under warranty, potentially reducing the financial impact on airlines.

Boeing has issued Special Attention Requirements Bulletin B787-81205-SB250302-00 RB, Issue 001, dated August 21, 2024, which outlines the procedures for inspection and repair. This document serves as the technical basis for the FAA’s directive.

Photo: Boeing

Legal Authority

The FAA issues this directive under its aviation safety authority granted by Title 49 of the United States Code. The agency has determined the proposal would not have significant federalism implications under Executive Order 13132 or substantial economic impacts on small entities.

After the comment period ends, the FAA will review feedback before issuing a final directive. Once implemented, airlines must comply within the specified timeframes unless they receive approval for alternative methods of compliance from the FAA.

Photo: By Toshi Aoki – JP Spotters; Wikimedia Commons

Bottom Line

The FAA’s proposed directive addresses a critical safety issue with Boeing 787 lavatories where corrosion on lower fitting assemblies could cause these units to detach during high g-force events.

If implemented, the directive will require airlines to conduct detailed inspections of the 8 lower fitting assemblies and centerline partition threshold of affected Jamco family 95/96 lavatories, perform necessary repairs, and update their maintenance programs.

Airlines have until May 22, 2025, to provide comments on the proposal. This action is necessary to prevent potentially serious injuries to passengers and crew, as well as to ensure clear evacuation routes remain accessible during emergencies.

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