Handling a balloon properly and gently will increase its life. In addition to Preventive Maintenance (defined narrowly by the FAA) there are many other factors which will prolong your balloon's life.
In our repair station we often repair the results of improper handling and inappropriate operational techniques. These factors, which are not usually considered maintenance, have much to do with the life of a balloon.
Storage. Heat and light are bad for nylon. Mildew forms on envelopes that are stored damp and warm; fabric will degrade if an envelope is stored in a too hot environment.
Baskets that are allowed to sit wet may rot. If stored in a hot, dry environment, rattan may become brittle. Balloons should be stored in a dry, dark, cool place, preferably on a pallet so air can circulate around it. If you store your basket in a dry, hot climate, place a bucket of water inside and cover the basket with an opaque cover. If you store your balloon in an enclosed trailer, the trailer should be light-colored, and parked in the shade. Venting should allow air to circulate. A closed, dark trailer sitting in the sun will become an oven and the heat will degrade the envelope and dry out the basket. Don't store the envelope in the basket as it may warp the sides of the basket.
Handling. We repair a lot of "gorilla" damage. The way a balloon is handled will affect its life. Don't drop the balloon from its transport vehicle onto the launch site. Don't drag the balloon envelope bag across the ground, carry it. Don't drag basket skids on pavement. Don't walk on the fabric, even if it's laid-out on grass; the pre-flight inspection can be done from the top opening or from a side vent without walking on fabric. If your balloon has a skirt, learn to coil the hoop to form relaxed loops so it doesn't break or become kinked. Kevlar cables require special attention; don't bend or braid them, get them wet, or overheat them. Don't step on any cables, kevlar or steel. If you are using volunteer crew, explain to them carefully your procedure for inflating and packing your balloon, and politely ask them not to step on fabric, pull ropes, or do anything without your specific request.
Transportation. If you tie your balloon to your vehicle or trailer, devise a system that doesn't crush the wicker-work or basket edge. Cover the basket to protect it from dirt and sunlight. Use a bag to protect the heater valves from dirt and dust during transportation. Don't travel with Raven/Aerostar or TBW uprights assembled in the basket attachments.
Separate the "super-structure" from the basket so the quick-pin aluminum holes don't wear prematurely.
Launch Site. Check for objects at the inflation site that may damage the fabric. Clear the site of sharp rocks, glass and sticks. Don't inflate on pavement unless you have no choice, or use a heavy tarp.
Layout. Pull only on load tapes, cords, or handling lines, preferably at strong points such as the junction of load tapes.
Inflation Fan. A large, high-powered fan run at high RPM will weaken the fabric in the mouth of a balloon over a period of time by "beating it to death". Two-stroke fans, or poorly-maintained fans will blow pollution into the envelope, shortening fabric life.
Inflation. Don't inflate with one long burn. It's hard on the heater, skirt or scoop, mouth fabric, (and crew). Don't rush; fabric is often burned or "cooked" at the skirt and mouth of the balloon because the pilot becomes frantic.
Flying Practices. Operate at low temperatures. Don't make long burns. If you splash-'n-dash, make sure your basket is completely dry before storage so skids and wickerwork don't rot, and connecting cables don't corrode. Fly as light as possible. Don't carry unused, unnecessary items in your basket (such as tools you can only use on the ground, champagne you can only drink on the ground, fire extinguishers that won't work).
Pack-up. Don't drag lines across basket or through fabric. Remove rocks and debris that might wear holes during transportation, and vegetable matter that may mold during storage. Re-position control lines during deflation to avoid snagging and tearing during layout.
General Practices. Don't sit on the side of the basket; this will distort the shape and weaken the rattan. Remind people not to step on rattan and leather. Keep your rattan clean; rocks, gravel and sand cause wear, and mud may start mold or rot. Protect fuel hoses, tanks and basket from chafing. Don't fuel through heater hose; this wears fittings. Use separate adapters and hoses for fueling. Aircraft heater lines are expensive. Change batteries annually so they don't corrode. Fix holes in envelope bag to prevent damage to envelope fabric. Don't varnish pure rattan; this causes it to dry out and become brittle. Don't over tighten P.O.L. fittings, and keep them clean so debris won't dent or mar the soft brass.
A little common-sense attention and maintenance will help prolong the life of your balloon, giving you more enjoyment at less cost.