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Captain reports a B757-200 was returned to the flight line in dangerous condition after a fuselage crown skin repair. The cockpit window tracks; cupholders; radio panels; speakers; seats and rudder pedals were littered with aluminum shavings and debris. Concerns that turbulence or explosive decompression could cause aluminum to get in pilots' eyes or lungs were raised.
| Attributes | |
| ACN | 963332 |
| Time | |
| Date | 201108 |
| Local Time Of Day | 1801-2400 |
| Place | |
| Locale Reference | ZZZ.Airport |
| State Reference | US |
| Environment | |
| Light | Night |
| Aircraft 1 | |
| Make Model Name | B757-200 |
| Operating Under FAR Part | Part 121 |
| Flight Phase | Parked |
| Component | |
| Aircraft Component | Fuselage Skin |
| Person 1 | |
| Function | Pilot Not Flying Captain |
| Qualification | Flight Crew Air Transport Pilot (ATP) |
| Events | |
| Anomaly | Aircraft Equipment Problem Critical Deviation - Procedural FAR Deviation - Procedural Maintenance Deviation - Procedural Published Material / Policy |
Narrative:
Company B757-200 aircraft was returned to the [flight] line in dangerous condition after [fuselage] crown skin replacement. The cockpit had aluminum chips and shards left behind by drilling and/or machining operations. The window tracks; cupholders; radio panels; seats; rudder pedals and many other areas were littered with the aluminum debris. This was a dangerous condition because in the event of explosive decompression; or moderate/severe turbulence; or other event; the aluminum [chips/shards] could get in the pilots' eyes and/or lungs with associated injury or crewmember incapacitation. It took about twenty minutes for cabin cleaners to completely vacuum the cockpit.
Original NASA ASRS Text
Title: Captain reports a B757-200 was returned to the Flight Line in dangerous condition after a fuselage crown skin repair. The cockpit window tracks; cupholders; radio panels; speakers; seats and rudder pedals were littered with aluminum shavings and debris. Concerns that turbulence or explosive decompression could cause aluminum to get in pilots' eyes or lungs were raised.
Narrative: Company B757-200 aircraft was returned to the [Flight] Line in dangerous condition after [fuselage] crown skin replacement. The cockpit had aluminum chips and shards left behind by drilling and/or machining operations. The window tracks; cupholders; radio panels; seats; rudder pedals and many other areas were littered with the aluminum debris. This was a dangerous condition because in the event of explosive decompression; or moderate/severe turbulence; or other event; the aluminum [chips/shards] could get in the pilots' eyes and/or lungs with associated injury or crewmember incapacitation. It took about twenty minutes for cabin cleaners to completely vacuum the cockpit.
Data retrieved from NASA's ASRS site as of April 2012 and automatically converted to unabbreviated mixed upper/lowercase text. This report is for informational purposes with no guarantee of accuracy. See NASA's ASRS site for official report.