{"id":"F2006B06446","name":"AD/R22/41 Amdt 1 - Upper Steel Tube Frames - 2","slug":"ad-r22-41-amdt-1-upper-steel-tube-frames-2","collection":"legislative_instrument","jurisdiction":"commonwealth","status":"in_force","isInForce":true,"actNumber":null,"makingDate":null,"administeringDepartment":null,"currentVersion":{"id":47886,"registerId":"commonwealth-F2006B06446-current","compilationNumber":null,"startDate":"2026-04-02","status":"InForce","reasons":null,"registeredAt":null},"sections":[{"sectionNumber":"1","sectionType":"section","heading":"AD/R22/41 Amdt 1 - Upper Steel Tube Frames - 2","content":"COMMONWEALTH OF AUSTRALIA (Civil Aviation Regulations 1998), PART 39 \\- 105 CIVIL AVIATION SAFETY AUTHORITY\n\nSCHEDULE OF AIRWORTHINESS DIRECTIVES\n\n![](image.001.png)  \nRobinson R22 Series Helicopters\n\nAD/R22/41\n\nAmdt 1\n\n  \n\nUpper Steel Tube Frames - 2 2/96 DM\n\nApplicability: All model R22 helicopters with P/N A020-2 steel tube frames serial numbers 0400 and higher installed.\n\nNote: The A020-2 frames below serial number 0400 are subject to inspection according to AD/R22/12 Amdt 2.\n\nRequirement: Remove the centre rear cowling skin, P/N A032-3, above the upper steel tube frame, P/N A020-2. With the aid of a torch and a large mirror (greater than 50 mm diameter) visually inspect all welds and tubing of the A020-2 frame for cracks or corrosion.\n\nPay particular attention to areas indicated in the figure below (from figure 2-10 of the Robinson R22 Maintenance Manual). Replace the centre rear cowling skin, P/N A032-3, at the completion of the inspection.\n\n![](image.002.png)  \n\nCOMMONWEALTH OF AUSTRALIA (Civil Aviation Regulations 1998), PART 39 \\- 105 CIVIL AVIATION SAFETY AUTHORITY\n\nSCHEDULE OF AIRWORTHINESS DIRECTIVES\n\nCompliance: 1. a. For aircraft used in aerial work operations: Inspect before 25 hours time in service after 20 December 1995. Re-inspect at intervals not to exceed 25 hours time in service.\n\nThe initial inspection must be done by a licensed aircraft maintenance engineer. Subsequent inspections may be performed by the pilot in command except where the aircraft is undergoing an inspection for maintenance release. A copy of this Directive must be carried in the aircraft and the required inspections marked on the maintenance release.\n\nAn aerial work aircraft is to include any aircraft with an unknown history of operation since new or since overhaul of the A020-2 frame. Aircraft which have been used for aerial work for any period of time since new or since the last overhaul of the A020-2 frame are also to be classed as aerial work aircraft.\n\n1. b. For all other aircraft operations: Inspect before 100 hours time in service after 20 December 1995. Re-inspect at intervals not to exceed 100 hours time in service.\n\nBackground: Fatigue cracks were found on early A020-2 frames in areas that may not have been included in regular maintenance. These areas have now been included in the normal 100 hourly inspection. The early frames have special inspection instructions in the Robinson R22 Maintenance Manual and are covered by AD/R22/12 Amdt 2. All frames also have a retirement life in the Maintenance Manual which is mandatory.\n\nThe Authority received reports that indicated later A020-2 frames were also failing before reaching the retirement life. This Directive was raised to highlight the directed visual inspection in the Maintenance Manual for later A020-2 frames.\n\nSince issue of this Directive several more frames have been found cracked and two reports of frames failing in flight have been received. Most failures occurred on aircraft used in mustering roles in which the fatigue loads on the frame may be more severe. This reduces the fatigue life and requires more stringent inspections.\n\nThis Amendment reduces the visual inspection interval for aircraft engaging in aerial work. An immediate inspection is recommended if any unusual vibration is felt when the aircraft is in flight.\n\nThe inspection intervals may be extended if the frame is strengthened appropriately. Any such scheme must be approved through a CASA District Office and by the manufacturer before being incorporated in the aircraft.","sortOrder":0}],"analysis":{"flash_summary_failed":{"failed":true,"reason":"Unauthenticated. Configure AI_GATEWAY_API_KEY or use a provider module. Learn more: https://ai-sdk.dev/unauthenticated-ai-gateway","source":"analysis-cron"},"kimi_summary":{"content_quality":"ok","complexity_score":3,"scope_assessment":{"changed":true,"description":"This is Amendment 1 to the original AD/R22/41. The original directive established inspection requirements for upper steel tube frames. This amendment significantly tightens the inspection regime specifically for 'aerial work' operations (reducing intervals from 100 hours to 25 hours) based on new evidence of in-flight failures and cracking discovered since the original issue. The scope has narrowed to target high-stress operations while maintaining the original 100-hour interval for general operations."},"complexity_factors":["Multiple operational categories with different compliance intervals (aerial work vs. general operations)","Nested conditions for who can perform inspections (licensed engineer first, then pilot, except during maintenance releases)","Cross-reference to another Airworthiness Directive (AD/R22/12 Amdt 2) for earlier serial numbers","Conditional extension clause requiring dual approval (CASA District Office + manufacturer)","Specific part numbers and serial number cutoffs that limit applicability","Reference to external document (Robinson R22 Maintenance Manual figure 2-10) for inspection areas"],"plain_english_summary":"This safety directive mandates regular visual inspections of the upper steel tube frame (A020-2, S/N 0400+) on Robinson R22 helicopters to check welds and tubing for cracks or corrosion. Aerial work operators must inspect every 25 FH, others every 100 FH; the first check must be by a licensed aircraft maintenance engineer, later checks may be done by the pilot. It responds to in‑flight frame failures, requires onboard retention and logbook recording, immediate checks after unusual vibration, and only allows interval extensions with approved strengthening modifications."},"flash_summary":{"complexity_score":5,"scope_assessment":{"changed":true,"description":"This amendment tightens and clarifies inspections for later-production A020-2 frames (serial 0400+). Mechanically it shortens the visual inspection interval for aerial work aircraft from the standard 100 hours to 25 hours, mandates initial inspection by a licensed engineer, and highlights directed inspection areas from the Maintenance Manual. It also permits interval extension only after structural strengthening approved by CASA and the manufacturer."},"complexity_factors":["Different inspection intervals depending on operation type (25 hours for aerial work; 100 hours for others) (Compliance: 1.a–1.b)","Qualification split for who may perform inspections (initial inspection by licensed aircraft maintenance engineer; subsequent inspections may be by pilot in command) (Compliance: 1.a)","Applicability limited by part number and serial number (A020-2 frames, serial 0400 and higher) (Applicability)","Specific physical access and technique required (remove centre rear cowling P/N A032-3; inspect with torch and mirror; attention to specified figure) (Requirement)","Cross-reference to the Robinson R22 Maintenance Manual and an earlier directive for lower serial numbered frames (Background; Note)","Operational classification rules that expand the aerial work category (unknown history, any prior aerial work use) create administrative ambiguity in aircraft categorisation (Compliance: 1.a)","Route to extend inspection intervals requires approval by CASA District Office and manufacturer, creating discretionary administrative steps (Background)","Administrative requirement to carry a copy of the Directive in the aircraft and record inspections on the maintenance release (Compliance: 1.a)"],"plain_english_summary":"This airworthiness directive requires removal of the centre rear cowling and a directed visual inspection (torch + large mirror) of the A020‑2 upper steel tube frame on Robinson R22 helicopters, and sets different inspection intervals depending on operation. \n\nIt applies to R22s with P/N A020‑2 frames, serial number 0400 and higher, affects owners, operators, pilots and maintenance engineers, and shortens inspection frequency for aircraft used in aerial work because fatigue cracks and in‑flight frame failures were reported."}},"importantCases":[],"_links":{"self":"/api/acts/ad-r22-41-amdt-1-upper-steel-tube-frames-2","history":"/api/acts/ad-r22-41-amdt-1-upper-steel-tube-frames-2/history","analysis":"/api/acts/ad-r22-41-amdt-1-upper-steel-tube-frames-2/analysis","conflicts":"/api/acts/ad-r22-41-amdt-1-upper-steel-tube-frames-2/conflicts","importantCases":"/api/acts/ad-r22-41-amdt-1-upper-steel-tube-frames-2/important-cases","documents":"/api/acts/ad-r22-41-amdt-1-upper-steel-tube-frames-2/documents"}}