Figure 6-7a. Example of good launch site. The pilot would have adequate clearance above the power lines at the far end of the field,
as well as more than adequate area to layout the envelope.
Figure 6-7b. Example of a poor launch site. The pilot would have a very short area to lay out. There are obvious obstacles, such as the
trees and cell phone tower, which create hazards to a safe launch.
Landing Sites
The best launch site is of little use if there are no appropriate landing sites downwind. Many pilots examine their flight
path from the perspective of the landing area, particularly in an area of few landing fields, and “reverse plan” their launch
site in order to make the appropriate choice of launch sites. Occassionally, this may require using a launch site that may
be somewhat less than desirable. As long as the launch can be made safely, with appropriate obstacle clearance, this is
perfectly acceptable.
Launch Site Surface
After determining the flight direction, the next condition that determines the details of the balloon layout is the actual
launch site surface. Of course, all pilots want to lay out their balloon on clean, dry, short, green grass. Most pilots are
not that fortunate unless they have their own launch site and never fly from different places. Wise pilots modify their
techniques according to available conditions, or they have more than one layout procedure to adapt to various launch sites.
Whether flying from a regular launch site, a brand new location, or from an assigned square at a rally, check the ground
for items that may damage or soil the balloon. Look for and remove nails, sharp rocks, twigs, branches, and other foreign
objects. If there are patches of oil or other substances, cover them with pieces of carpet, floor mats from the chase vehicle,
tarps, or the envelope bag. Some pilots cover the ground where they lay out their balloon with a large tarp every time they
fly.
Unless flying at a known site, do not assume it is all right to drive the chase vehicle directly onto the launch area. There are
some locations (a soft athletic field, for example) where it is necessary to carry the balloon onto the launch area. If using
private property, it is necessary to get permission to use the property for flight activities. This may be the first experience
with landowner relations, and the considerate pilot takes action to minimize their impact on the landowner’s property.
Landowner relations are an important part of ballooning, and are discussed in greater detail later in this chapter.
Balloon Placement & Wind Direction
Consider the wind direction before the balloon is unloaded from the chase vehicle. Take into account the surface wind at
the time of cold inflation to avoid carrying a heavy balloon bag and basket around. A “Murphy’s Law” type of rule is that
the wind always changes during inflation. Local knowledge is invaluable. If other balloons are around, check with the most
experienced local pilot.
A wind change at or shortly after sunrise is normal in many places. If the balloon is laid out prior to sunrise, a wind change
is likely. If flying in a new area, it is beneficial to watch the local pilots, as they have knowledge of local conditions and
idiosyncrasies. Some general trends are that air usually flows downhill or down valley first thing in the morning, and
air usually flows from cold to warm in the morning. The air drainage may stop very shortly after the sun rises and starts
heating the ground. The early morning wind may come from a different direction than the prevailing or predicted wind.
Some local pilots may lay their balloons out in a direction that does not match the airflow at the time, but that corrects 15
to 30 minutes later when the sunrise change occurs and the inflation starts.
Removing the Balloon from the Vehicle
Once the specific location on the launch field has been determined, the balloon should be removed from the vehicle, or
unloaded from its trailer, and prepared for flight. [ Figure 6-8] Good procedures and habit patterns formed here minimize
the amount of lifting of balloon components, and reduces the wear and tear on the crew and the pilot, as well as the
equipment itself. Despite being a lighter-than-air aircraft, the packed balloon and basket are heavy; the average sport
balloon system can weigh over 550 pounds.
Figure 6-8. Unloading the basket and moving the vehicle forward minimizes equipment carrying.
One method is for the pilot to establish the specific location and direction of layout, and direct that the basket be placed
there. The transport vehicle maneuvers to allow the basket to be removed and placed at the pilot’s discretion, and then
pulls forward about 15 or 20 feet to allow for the envelope bag and inflator fan to be removed and placed on the ground.
The vehicle may then be removed from the launch site, or moved to the back of the basket to serve as a tie-off point for
the balloon’s quick-release system. This method minimizes the amount of lifting and carrying of heavy components. When
used in reverse, it allows for the system to be packed up at the end of the flight, and kept ready for a future flight.
Assembly
If the basket is disassembled for transport and handling, it must be assembled in accordance with the flight manual prior to
layout. The pilot, using the checklist, should either perform these functions or carefully supervise them.
Basket
Once the basket is appropriately placed, it is necessary to attach the uprights and burner frame (as appropriate). Each brand
of balloon is slightly different, and the balloon’s flight manual should be checked for the specific procedures. Some balloon
baskets must be placed on their side to install the uprights and burner, while some may be left standing upright. Either
way, after the components are installed, they should be checked for installation, integrity, security, and general condition.
Burner and Fuel System
If not accomplished in the previous step, the burner(s) (or heater) should be mounted and connected. Retaining pins,
as applicable, must be mounted, and fuel lines connected between the burner and the tanks. The practice of using an
adjustable wrench on fuel line fittings is discouraged; while convenient, these wrenches usually cause excessive wear on
the fittings over time, and may result in damage or early replacement. It is usually better to use the correct size open-end
wrench. Fittings do not need to be heavily torqued into place; this is a common error with newer pilots. A good fitting
usually seals with little more than finger-tight force. Anything more may indicate corrosion or a damaged flange seal in
the fitting. [Figure 6-9]
Figure 6-9. Burner installation on a Lindstrand.
It is appropriate to check for leaks in the fuel system at this point; this should be a checklist item. The pilot opens the fuel
tank valves and checks each connection, at both tank and burner, by using a “sniff test.” The odorant in propane, ethyl
mercaptan, has a very distinctive odor and is relatively easy to detect. The burner should also be examined to ensure that no
fuel is leaking from fittings, pressure gauges, or interior plumbing. Once satisfied that there are no leaks, the fuel may be
turned off and the pressure bled off. The basket should then be placed in a vertical position to prepare for the next function
check.
Burner Check
Most manufacturers require burner checks as a necessary part of an equipment function check and are indicative of good
habit patterns. Each system has a specific procedure, appropriate to that particular system, which is outlined in the flight
manual for that model of balloon. In general, each burner, including the pilot light, is checked individually for correct
operation to ensure that the burner is working properly. Each burner is checked using each fuel tank, and all backup
systems should also be checked for correct function and operation.
As an example, assume a single burner balloon with three tanks connected into a common fuel line (tanks in parallel).
The pilot would first light the pilot lights and check for correct operation. Then, one tank would be opened, and the blast
valve activated. The pilot checks for correct operation, smooth blast valve movement, and for pressure in the fuel system,
as excessive loss of pressure may be indicative of a fuel tank or line problem. This procedure should be repeated for each
tank, closing off the first tank when moving to the second, and so on. After all tanks are checked, then the backup system
(Fire2™, Whispervalve™, Liquid Fire™, Metering Valve, etc.) should also be tested. Once all systems are checked for
functionality, then the tanks should be closed, pressure released from the fuel system by burning off the fuel, and the basket
placed on its side in preparation for attaching the envelope. (NOTE: At no time should all of the tanks in a parallel-plumbed
system be opened at once. In the event of a fuel leak or ruptured hose, there are three or more tanks feeding the leak. This
is an extremely hazardous practice.)
Pilots should also note that there is a growing trend towards the use of inflation, or “pony” tanks, used to supplement
onboard fuel for inflation. Use of an inflation tank allows the pilot to launch with completely full tanks, as the additional
tank is either temporarily plumbed into the balloon’s fuel system by the use of a quick-disconnect fitting, or hoses are
switched around at the burner fitting. There is no manufacturer’s written procedure available for the use of an inflation
tank, and the procedure is strongly discouraged. Of perhaps greater concern is the mindset that the one or two gallon
advantage this gives the pilot, is of greater concern than the safety aspect of the procedure. If a pilot consistently requires
these one or two gallons of fuel to safely conduct a flight, then there are possibly other performance planning factors being
neglected.
Most pilots conduct a burner check at the beginning of each flight. Others, if conducting multiple flights over a relatively
short period of time (a weekend balloon rally, for example), may do a full burner check for the first flight only, and then
only check for leaks on each remaining flight. This practice, while common, may violate the manufacturer’s operations
manual and invites problems; it is best avoided.
Instrument Checks
It is appropriate to check the instruments at this point. Virtually all instrument systems currently in use require battery
power; it is wise to check the instruments, and ensure that the batteries provide sufficient power to operate them. There
is nothing more frustrating than being ready to fly and finding that the instruments do not work. After the instruments
are checked for operation, they may be mounted in the basket. Some pilots choose to set the altimeter at this time; the
barometric pressure should be set according to the information gathered during the weather briefing. In the absence of a
barometric pressure setting, the altimeter should be set to the appropriate field elevation. The only time that the altimeter
may be set to zero is when the balloon is being flown from an ocean beach; 14 CFR part 91, section 91.121 provides
clarification on this requirement. This is necessary to avoid airspace issues. [Figure 6-10]
Figure 6-10. The altimeter should be set to barometric pressure, if available, or to the field elevation
At this point, the basket is on its side with the instruments mounted and ready for the envelope to be attached. The pilot
and crew should open the envelope bag, remove the suspension cables and attachment hardware (carabiners, “A-blocks,”
or toggles), and attach the bottom of the envelope to the basket superstructure in accordance with the manufacturer’s
instructions. Care should be taken that cables are not twisted and are free of damage, kinks, loose wires, or missing
sheathing (found on Kevlar® suspension cables). Once the envelope is attached, the hardware should be checked for
security and the envelope laid out for inflation.
Layout
There are many variations of laying out a balloon and preparing it for inflation. The manufacturer of the balloon or the
way the balloon is assembled sets some of these inflation styles. The launch site surface, the order in which the balloon
is assembled, and how the balloon is removed from the chase vehicle have a bearing on the way the preflight layout and
inspection proceeds. There is no one best way to lay out a balloon, as there is no one best way to inflate a balloon. The two
most common ways to prepare the balloon for cold inflation are to spread it out or inflate from a long strip.
The pilot should be mindful of current conditions prior to removing the envelope from its bag. It is wise to take a moment
and walk around the launch site to check the surface for any debris that may damage the balloon.
As a cautionary note, do not drag the envelope bag along the ground when pulling the envelope out. Many envelopes have
holes and tears caused by being dragged over sharp objects while getting the envelope out of the bag. Lift the bag clear of
the ground and carry it unless the launch surface is perfect with no sharp objects or dirty spots.
Spread Layout
The spread layout method for inflation is the most widely used method. By handling the envelope with the load tapes, the
fabric is pulled away from the center until the envelope takes its normal shape while still flat on the ground. Exercise care
when sliding the fabric across the ground to avoid causing damage.
All balloons have an even number of load tapes. By using the number on the load tape when spreading the envelope, the
envelope can be arranged in a proper position for inflation. With one crewmember on each side of the envelope fabric, start
at the mouth and travel the length of the appropriate load tape, pulling the fabric taut up to the equator. This allows the
bottom to be laid out flat. Be careful to handle only the load tapes when positioning the envelope because pulling on the
fabric could cause damage. Holding a load tape and flapping up and down gently helps avoid tears and other damage while
spreading the envelope. This action traps a small bubble of air which floats, rather than drags fabric and keeps the balloon
cleaner and easier to pull. [Figure 6-11]
Figure 6-11. A spread layout
Check the deflation system at this time and properly position it in accordance with the balloon flight manual. While the
envelope is filling with air, the crew can assist the process by lifting upward on the load tapes, allowing more cold air to
pack the envelope. This method allows the envelope to deploy smoothly and easily, even with a small inflation fan.
Strip Layout
When inflating on pavement or a small or narrow launch site, many pilots prefer not to deploy the envelope on the ground.
Instead, they prefer to pull the envelope straight out from the basket, making sure the top gore is on top its full length,
and to inflate the envelope entirely with the fan. This may require a larger fan, depending on the size of the balloon and
envelope material. [Figure 6-12]
Figure 6-12. A strip layout.
Once the balloon is stretched out, ensure the control lines (deflation, cooling, or rotating) are correctly attached to the
basket according to the manufacturer’s instructions. This method minimizes handling the fabric on a rough or dirty surface.
It requires more diligence by the ground crew to ensure it deploys correctly.
Progressive Fill
Inflation out of the bag is a coordinated technique in which the envelope is cold inflated directly out of the bag. With the
envelope suspension connected to the basket, it is pulled progressively out of the bag as the fan is running, inflating the
envelope as the crew slowly, with pauses, carries the balloon bag away from the basket while the envelope fills. Another
variation, the progressive fill, has the crew holding the envelope in their arms, gradually releasing more and more of the
envelope, from mouth to top, until the very top of the envelope is released for filling. The progressive fill packs the lower
portion of the envelope with cold air, and exposes less of the fabric to the ground. This method generally results in a faster
inflation, but may create problems with attaching a parachute top or ensuring that lines are not tangled.
Inflator Fan Placement
The type of inflator fan needed for different layout techniques depends primarily on the amount of work required. The strip
layout method requires a large, strong fan to force the envelope into shape, while the spread layout method requires less
fan energy.
Fan placement and techniques are as varied as the pilots who fly. It may appear that every pilot has a slightly different
technique for placement and use of the fan, but the general principle is the same. The fan should be placed to the side of the
basket [Figure 6-13], with the air flow directed into the mouth of the balloon to inflate the envelope, but far enough back
to allow the airflow to “seal” the throat. This allows the most efficient use of the fan.
Figure 6-13. Placement of the inflation fan.
A method pilots use to determine the best placement of the fan is to attach small pieces of fabric or surveying tape on the
lower portion of the mouth, using safety pins in such a manner as to not create damage or holes. Then, the crew holds
the mouth of the balloon open with the fan running; if all pieces of the tape are pointing into the envelope, then the fan
is properly placed; however, if any of the tapes are fluttering back out the mouth of the envelope, this demonstrates that
the airflow is going into the envelope and coming back out again. This does not allow for a good inflation, and the fan
should be adjusted to correct this deficiency. This demonstration should be done without use of the burner, as the pilot may
inadvertently cause damage or start a fire. [Figure 6-14]
Figure 6-14. Determining correct inflation fan placement. Note that the strips of tape are generally pointing into the mouth. In this
case, the pilot would do well to incline the fan slightly towards the right side of the mouth, in order to better “seal” the envelope
opening, and get a more efficient inflation.
It is generally better to pack the balloon full of cold air. This makes a tighter mouth, which avoids burning fabric, and the
balloon may be less affected by a light wind when it is round and tight.
Safety Restraint/Quick-Release
The quick-release or safety restraint should be secured, with little or no slack in the line, to prevent possible damage or
injury in the event of a break or premature release. Every major balloon manufacturer specifies the approved method
for tying off. Balloon baskets, suspensions, load plates, and burner supports have been destroyed by improper tie-off in
light winds. When tying down for inflation, reference the balloon’s flight manual for the recommended procedures and
techniques. The use of a safety restraint is a recommended procedure for enhanced safety.
Passenger Briefing
Prior to inflation, a pilot should give passengers their first briefing for behavior during the flight and landing. Inform
passengers that during the landing they should stand in the rear of the basket where shown by the pilot (based on wind
conditions), facing the direction of flight, with feet and knees together, knees slightly bent, and holding tightly to the sides
of the basket. They are not to exit the basket until instructed by the pilot to do so. This procedure allows the passengers
to see the landing sequence, and is generally accepted throughout the ballooning community. In larger balloons, which
usually have compartmentalized baskets, some pilots encourage the passengers to face away from the direction of flight.
Either procedure is acceptable, as long as it is briefed prior to flight, and reinforced prior to landing.
The balloon is ready for inflation when the preflight preparation is complete. Excess equipment is stowed in the basket and
chase vehicle, and a radio check is completed.
Inflation
The inflation procedure takes the balloon envelope from a pile of fabric to an aircraft capable of lifting a load. The pilot’s
goal should be a smooth, controlled inflation that does not damage the environment, balloon, or harm the crew. At the end
of the inflation, the balloon should be upright, close to equilibrium, and ready to fly.
Inflation Styles
There are many different styles of inflation. Some pilots use one or two large fans to inflate the balloon fast and get it tight.
Some pilots prefer to fill the envelope slowly to give them time for preflight preparation. Some use many crewmembers;