A Boeing 747 can endure about 35,000 pressurization cycles and flights—roughly 135,000 to 165,000 flight hours—before metal fatigue sets in. 747s are retired after approximately 27 years of service.

The average operational lifespan of a Boeing 747-400 is typically between 25 and 30 years, though this is measured more accurately in "flight cycles" (one takeoff and landing) and "flight hours." A 747 is generally designed for a life of approximately 35,000 cycles and 135,000 to 150,000 flight hours. Once a plane reaches these limits, the metal in the fuselage and wings begins to suffer from "fatigue," requiring increasingly expensive structural reinforcements and frequent "Eddy Current" inspections to find hidden cracks. In 2026, most 747-400s have been retired from passenger service (replaced by more fuel-efficient twin-engine jets like the 787 or 777X), but many continue to live a "second life" as freight carriers. Cargo operators like Atlas Air or UPS often operate these aircraft for up to 40 years, as cargo flights involve fewer cycles than high-frequency passenger routes. Ultimately, the lifespan ends when the cost of the next "Heavy Maintenance Check" (D-check) exceeds the value of the aircraft, at which point it is usually sent to a "boneyard" for parts salvage and scrap.