You are right - it is almost impossible.
I finally was allowed to speak with a very kind supervisor. He read me the rule:
The maximum allowable TRANSFER POINTS for international travel is 4.
This means a max of 5 segments (not 4). Transfer point means anytime the flight number changes (not just a stop).
This is still very hard to deal with on international travel. I knew the whole USAir/Star Alliance thing had to be a ruse.
Originally Posted by kreeft
I have a routing right now that goes DCA-ORD-LAX-KIX-BKK and on the return BKK-SIN-HKG-SFO-PHL-DCA. I find it really hard to believe that even the limit is 5, you can't get from KC to Phuket in 5 segments