The Federal Air Transport Agency ordered airlines to carry out an urgent inspection and repair of the sides.
14 Sukhoi Superjet 100 aircraft have revealed design flaws in the fuselage mounting. The aircraft manufacturer, PJSC Yakovlev, warned the Federal Air Transport Agency about this. The agency has already ordered airlines to inspect 14 aircraft manufactured in 2016. The problem concerns the fasteners between the cockpit and the aircraft's front door. The suspected airliners are operated by Yamal, Rossiya, Azimut airlines and a number of others. During operation, they may develop cracks, deformations and folds in the problem area of the fuselage. If these defects are revealed during the inspection, it is prescribed to remove the sides from flights for repairs.
What problems can the Superjet have with the fuselage
There is a risk of structural defects in the fuselage on 14 Sukhoi Superjet 100 (RRJ-95) aircraft, according to a letter from Yakovlev PJSC to the Federal Air Transport Agency dated May 15, 2025. Based on this appeal, the Federal Air Transport Agency issued an airworthiness directive on August 1, which instructs airlines to inspect aircraft and, if necessary, repair them. Izvestia reviewed both documents.
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"During the operation of aircraft of the RRJ-95 type, deviations of the standard fuselage design along the junction of stringers 42-44 with the double beam of the frame 12 of the F2 compartment from the design documentation were revealed," the directive says.
Andrey Dobryakov, deputy head of the Federal Air Transport Agency, ordered operating organizations to carry out maintenance work on aircraft with serial numbers 95104-95117 (14 in total), which may have design deviations, according to his letter to the airline. All aircraft of this batch were released in 2016.
In the absence of fasteners for stringers on already in use boards, it is prescribed to limit their airworthiness until technical deviations are eliminated. Especially for these repairs, Yakovlev issued a service bulletin with an accurate description of the algorithm of the technicians' actions.
Mounting problems on some SSJ-100s may occur between the cockpit and the passenger door, the bulletin notes. To check the aircraft, it is necessary to conduct a detailed inspection of the skin, as well as frames, beams and stringers (bearing elements of the fuselage) for creases, cracks, deformations, loosening of bolted or riveted joints.
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To do this, it is necessary to dismantle the doorway cladding, remove the toilet module and remove the thermal insulation mats. This way, the technician will have access to the structural elements that he must inspect. It is necessary to use special tools — a telescopic mirror, a magnifying glass and a flashlight — to detect possible micro-damage.
If the design deviations are confirmed, the aircraft should be sent for repairs.
The Sukhoi Superjet 100 (SSJ-100) is currently the only mass—produced Russian aircraft that was developed after the collapse of the USSR with the participation of European companies in avionics, engines, etc. The aircraft was produced in 2007-2022, and an import-substituted SSJ-New variant has been actively developed since 2022.
According to the portal information russianplanes.net SSJ-100s with the numbers specified in the directive are flown by Rossiya airlines (one flight), Azimut (one flight), Yamal (five flights). Several aircraft are in storage with various organizations, including the Sukhoi Design Bureau, Yamal, etc.
Photo: TASS/Sergey Savostyanov
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Izvestia reference
In total, 232 SSJ-100 aircraft have been produced in Russia, and about a hundred are in operation with valid airworthiness certificates. After a number of aviation accidents, the IAC focused on the shortcomings of the landing gear design, which in case of accidents could damage the fuel tanks. In the import-substituted version of SSJ-NEW, they plan to change the chassis designs.
The Azimut press service confirmed to Izvestia that the airline has only one aircraft under additional inspection, which does not operate regular flights.
"The inspection of the doorway on this aircraft will be carried out in accordance with the work regulations and does not require an urgent stop," they said. — Therefore, nothing threatens the regular schedule.
As the United Aircraft Corporation (UAC, part of Rostec State Corporation) told Izvestia, Yakovlev, as an aircraft developer, initiated the issuance of this mandatory airworthiness directive for SSJ-100 aircraft, acting in close cooperation with the Federal Air Transport Agency.
"The document is preventive in nature and is aimed at maintaining the airworthiness of the existing fleet of aircraft," the UAC noted.
The work includes, among other things, modification of aircraft systems and enhanced control of critical structural elements. This approach guarantees the safe operation of aircraft, they noted.
Photo: TASS/Sergey Savostyanov
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According to the UAC, the extension of the deadlines for individual works is accompanied by the introduction of additional operational procedures to ensure trouble-free operation of airliners.
Izvestia sent inquiries to the Federal Air Transport Agency, Rostec, and the airline.
Why are airworthiness directives issued?
—Airworthiness directives are issued for urgent execution when the flight safety risk is assessed as high," Andrey Patrakov, founder of the RunAvia flight safety service, told Izvestia.
On the basis of such directives, aircraft may be suspended from flights. These are the limitations of airworthiness, he added.
"During the operation of aircraft, production and design defects are sometimes found that did not manifest themselves during the tests," said Oleg Panteleev, Executive Director of the Aviport agency.
In this case, it was assumed that the fasteners were loose, which could potentially lead to problems, the expert said. According to him, a similar logic is implemented in recall campaigns in the automotive industry. It's not a fact that a particular board has a defect, but it needs to be checked to make sure it's safe.
Photo: TASS/Kirill Kukhmar
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— Most often, design deviations occur due to manufacturing violations, — said Andrey Patrakov.
Judging by the description, this is a difficult repair, the expert notes.
Meanwhile, experts point out that airworthiness restrictions and repairs are part of the routine work for all developers.
"Both domestic and foreign airplanes, helicopters, and engines almost constantly show some defects," Oleg Panteleev notes. — For mass types of aircraft, the number of directives can be in the dozens. In the vast majority of cases, this does not lead to prolonged downtime of aircraft.
According to Andrey Patrakov, the most sensational incident with deviations in the production of the fuselage is the emergency exit plug on the Boeing B737—MAX that flew off in flight in 2024. During the inspection of the aircraft, it turned out that the hatch caps were installed improperly on many sides.
Vladimir Gavrilov
Stanislav Fedorov
