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Structural safety is an evolutionary accomplishment, and attention to detail design features is key to its achievement. A multitude of design considerations is involved in ensuring the structural integrity of Boeing jet transports that have common design concepts validated by extensive analyses, tests, and three decades of service. The active service life of commercial airplanes has increased in recent years as a result of increasing costs for fleet replacements. As airplanes approach their design service objectives, the incidences of fatigue and corrosion may become widespread. Continuing airworthiness of the aging jet fleet requires diligent performance from the manufacturer, the airlines, and airworthiness authorities. This paper gives an overview of traditional Boeing maintenance-related activities, joint industry/airworthiness authority initiatives, and the anticipated benefits for future generations of commercial airplanes.

Economic and market conditions have resulted in the use of commercial jet airplanes beyond their original economic design life objectives. The average age of the world airline jet transport fleet has increased from 8 to 12 years since 1980. Standard Boeing practices to support continuing airplane structural integrity include inspection and overhaul recommendations contained in maintenance manuals and service bulletins. As airplanes exceed their economic design life objectives, the incidence of fatigue increases and corrosion may become more widespread. This presentation is focused on recent special activities to assess the condition of the aging airplane fleet and other joint Boeing, airline and airworthiness authority reviews of service bulletins, corrosion control programs, basic maintenance and supplemental structural inspection programs, and structural repair quality.