The world’s biggest commercial passenger aircraft, the Airbus SE A380, experienced an unexpected revival by carrying full capacities of travelers as global travel recovered following the pandemic. However, maintaining the aging giant aircraft in safe operation is turning into a costly challenge for airlines.
Twenty years following its first flight, regulatory notices requiring fixes, inspections, or part replacements for the large four-engine aircraft are increasing. Although some are administrative, like a requirement for regular equipment checks, others are more significant.
Defective escape slides, broken seals, and a damaged landing gear axle are included in 95 airworthiness notices for the A380, as reported by the European Union Aviation Safety Agency since January 2020.
That’s approximately twice the amount of directives for major Boeing Co. planes during the same time frame.
With a limited availability of newer, more fuel-efficient jets, airlines that have invested in the twin-deck A380 have few alternatives but to continue operating it. In its early years, the A380 represented a success of global cooperation, consisting of 4 million components manufactured by 1,500 companies around the world. Today, as it ages, the aircraft’s complexity is putting pressure on aviation’s already strained supply chains in the post-Covid period.
The A380 is a sophisticated aircraft that, due to its size, presents greater maintenance challenges than other planes,” stated the European Union Aviation Safety Agency in a release. “It is crucial for safety that there is no negative perception associated with issuing an airworthiness directive — safety should always be the top priority.
The agency stated that these instructions, which require actions to ensure an aircraft’s safety, “can differ significantly in terms of scope and urgency.” The number of airworthiness directives for various aircraft “is not a reliable way to compare them,” EASA noted.
Stranded Passengers
Nevertheless, the ability to transport 485 passengers or more means that delays due to mechanical issues can result in significant expenses and lead to a series of scheduling challenges. A Qantas Airways Ltd. A380 operating on the key Sydney-London route experienced a breakdown in Singapore on May 7 due to fuel-pump issues. The subsequent flight to London was delayed by over 24 hours, with passengers provided hotel accommodations.
That was at least the second instance of a fuel pump problem causing delays for QF1 in Singapore since Qantas resumed operations with its A380 fleet. Recently, Qantas travelers scheduled to leave Singapore on July 14 bound for Sydney on an A380 faced multiple days of delay due to technical issues. Efforts to get them on their way earlier were hindered by damage to another A380 at Sydney airport, where an airbridge collided with one of the engines.
A British Airways A380, registered as G-XLEB, remained in Manila for over 100 days recently. Following its return to London Heathrow in mid-June, it only operated for seven days within the subsequent 30, as reported by Flightradar24. However, starting next year, IAG SA-owned British Airways will initiate an interior renovation project, which involves updating the A380’s cabin facilities, indicating that the airline plans to continue operating the aircraft for many years.
Airlines that operate the A380 have few options for high-capacity aircraft. Boeing’s 777X has faced significant delays, while Airbus is struggling to produce long-haul A350s quickly enough. As a result, A380 operators are stuck with a superjumbo jet that is no longer in production and is expected to become increasingly costly and difficult to maintain. In online aviation communities, some airlines are becoming known for mechanical issues, flight cancellations, or overnight delays.
In a statement, Airbus mentioned that the A380 “remains in regular service with a strong degree of operational reliability, maintaining a 99% rate for the worldwide fleet during the last 12 months. Airbus is dedicated to offering complete technical assistance to clients to help them maximize efficiency with their A380 fleets, and this support will persist as long as the aircraft is in use.”
60,000 Hours
In the meantime, A380s are occupying space and requiring significant labor in workshops across the globe, worsening the scarcity of maintenance facilities for the broader commercial aviation industry. A thorough inspection of the large aircraft can require 60,000 hours of work, as reported by aircraft maintenance company Lufthansa Technik.
Qantas is sending certain double-deck aircraft to Dresden, Germany, for maintenance; British Airways takes theirs to Manila for repairs; and Emirates, the largest operator of A380s globally, handles some of its maintenance in China.
Several of the aircraft’s recent issues originated from extended ground storage during the pandemic, as airlines left their A380s parked in the Californian desert, central Spain, or the Australian wilderness.
An airworthiness directive issued by the European Union Aviation Safety Agency on May 16 required the immediate replacement of emergency inflatable escape slides. Separated seams, likely caused by exposure to moisture and heat while in storage, were identified as the issue. EASA warned that this defect could lead to severe, potentially fatal outcomes.
On April 7, the EASA mandated inspections of A380 aircraft following the discovery of a cracked sealant on components connecting the landing gear to the wings. A directive issued in April of last year required the replacement of certain landing gear axles after a rupture occurred on a plane that had been stored since 2020.
The viability of the A380 was already uncertain before the Covid-19 pandemic brought worldwide travel to a standstill in early 2020. The previous year, Airbus had ceased manufacturing due to lackluster sales.
As the spread of Covid-19 decreased and borders began to open, the A380 quickly found a renewed role. Travel increased significantly, and airlines such as Singapore Airlines Ltd., Deutsche Lufthansa AG, and Qantas once again recognized the plane’s unmatched capacity.
In a statement, British Airways described the A380 as “an essential component of our long-haul aircraft fleet. By collaborating closely with Airbus, we have observed steady annual improvements in its dependability.”
Qantas stated that the aircraft “plays a vital role in our global network, and we plan to operate them for many years ahead. Every Qantas A380 has undergone a planned major maintenance check in recent years, along with substantial improvements to the cabin interiors.”
Other A380 operators were hesitant to share specific information. Asiana Airlines Inc. stated, “matters concerning aircraft operations and maintenance are challenging to reveal publicly.” Korean Air Lines Co. mentioned that it “ensures its A380 fleet meets the highest safety levels, following all regulatory rules and manufacturer recommendations.”
Singapore Airlines stated that its 12 A380 aircraft play a key role in its operations but mentioned it “could not provide details.” The company noted that it collaborates with “Airbus and our suppliers to maintain the continued reliability and operability of our A380 fleet.”
Certainly, the A380 still has its supporters. Emirates, which has taken apart some A380s for replacement components, intends to continue operating the aircraft until the conclusion of the next decade. The airline’s president, Tim Clark, has compared the jet to a massive vacuum cleaner that can absorb passengers more effectively than any other plane.
Recent reliability problems are the latest challenge for a superjumbo that has consistently sparked debate. Travelers continue to appreciate the A380’s expansive cabin and impressive size. Airlines face difficulties in handling its logistical requirements—such as longer runways and larger hangars—as well as its mechanical issues.
Supply chain issues have caused the cost of components, maintenance, and engine repairs on all major aircraft to rise, according to Eddy Pieniazek, head of advisory at Ishka.
“Due to the A380’s large size and four-engine configuration, this rise in maintenance expenses has become even more apparent,” stated Pieniazek.
