BalloonLife,April 1999

52

REPAIR STATION

by Alan Sanderson

Non-DestructiveGround
Operations

Several phases of ground operation must be carried out properly
to prevent damage to the balloon system. In order to fly, the
balloon must be loaded into the chase vehicle, transported to the
launch site, unloaded, laid out, and inflated.After the landing,the
balloon must be deflated, packed up, loaded, transported home,
and stored. Improper operations during any phase can cause
minor damage to total equipment loss.

Loading/Unloading
Chasevehiclesrangefromopentrailersandpickups,to
closed trailers, vans, andChase Commanders. The system must
be loadedproperlytopreventequipmentdamage duringhan-
dling and transportation.Somevehicles havesharp edges that can
cutthroughenvelopebagsorwearholesinwickerorscuff
leather.Placepaddingaroundthewickertopreventscraping
during the loading or unloading process. Scrap carpeting is useful
as padding aroundthe basket and envelope bag. Protect the fan
cage from rubbing or flexing. Tie everything securely so nothing
willshift in the event of a suddenstop.

Transporting
While the system is being transported, it is subjected to road
vibrationandbumps. Anenclosedvehicleprotects thesystem
from wind and weather, but vibration can still do damage. Check
the fuelsystemandmove anyhosesthat are routed where they
will rub against anything that could wear or abrade them. If they
show significant abrasion theymust be replaced.
If the trailer subjectsthe balloontoa roughride, store the
instrument pack ina padded case. Store the burner ina padded
case or ina burner bagthat willkeepit from bouncing around.
Somelargeframeburnerscanbewrappedinpaddingand
strappedto the inside of the basket.
Loose items, suchasuprights,accessories, foldingchairs,
tables, andpicnic basketscaneasilyblow outof the backof a
vehicle. A basket cover can contain lightweight objects that may
flyoutofanopenvehicle.Picniccoolers,tarps,ceremonial
carpets,andchaseflagsaresomeexamples.Animproperly
secured basket cover can blowoff without much warning. Ifyour
basket is equipped with suedetrim, place an old sheet between the
suede andthe basket cover. The windwill cause a cover to flap

and polish all the nap off the suede. The sheet allows the cover to
rub without damaging the suede.
Stow the envelope bagcarefully. If it is nottightly closed,
and the wind catches a small corner of the envelope, it can easily
gift-wrap several vehicles onthe highway. A 70-MPH freeway
baginflationisa real disaster, bothfortheequipmentandany
other drivers in the immediate area. Store the envelope bag so its
opening isnot exposedto the wind.
Transport empty fuel cylinders with the valve and fuel level
gauge up. While a cylinderis full, propane surrounds the dip tube
andgaugefloatassemblyandabsorbsvibrations.Whenitis
empty, vibrations from the roadmake their wayto the dip tube
andfloatassembly.Inmostcylinders,thediptubeandfloat
assembly are supported only from the top ofthe cylinder,hanging
straightdown.Ifthecylinderislaiddown,theyareheldina
horizontalposition.Vibrationcaneventuallycausethefloat
assembly or the dip tube to breakoff inside the cylinder.

Assemblyand Layout
Most damage during layout is caused by debris on the launch
site, such as barbed wire, broken glass, and other trash, or people
stepping on the fabric. Check out the launch field for junk before
layingout the envelope.While pulling theenvelopeout of the
bag, be very careful of suspensioncable hardware.
Place a square of scrapcarpet under the side of the basket
beforeyoutipitover.Ifitisbigenough,italsoprovidesa
kneelingarea for the pilot.
Other layout damage isa3-cornerfabric tear causedbya
crewmember pulling on the parachute valve. When the envelope
ismilked, fabric maybecomecaughtin the “V” formedby the
bridle lines. When the crewmember pulls on the valve the caught
fabric willtear.Walkunder theenvelopetospreadthe fabric
beforepullingthevalvetopreventthisprob lem.Another
crewmember canhold the topopening closeduntilthevalve is
freed.Thenthevalvewillblowintoplacewithverylittle
assistance.

Packup
Aftera stand-uplanding, checkthe area downwindof the
balloon for trash. If the area is unsuitable, walk the balloon to a

53

BalloonLife,April1999

cleaner area before laying it down.
Therearetwo methods commonly used topackup an
envelope—Crew abuse, or “Dragthe Bag,”andthe caterpillar, or
the “Piccard Method.”

Drag the Bag
To start this procedure, two strong crew members carry the
envelope bag to the top (crown) of the envelope. The remaining
crew members holdup the envelope and stuff it intothe bag as it
isdragged toward the basket. Draggingthe bagacross theground
eventually wears ahole in thebottom.Anenvelopecan be
damaged by a hole in the envelope bag that exposes balloon
fabric. Handling the bag can tear or abrade any fabric that is
sticking through the hole.

The Piccard Method
I learned this method while crewing for a Piccard balloon
with the envelope bag inside the basket.
Place the bag onone sideof the envelope, about5 feet above
thethroat, withthe flap towardthe basket. Linethe crew upalong
the otherside ofthe envelope starting at thecrown, spaced
fingertip to fingertip facing the envelope. Each person picks up
theenvelopewithbotharms. The personatthecrown walksalong
the opposite side of the envelope to the bag, and the rest of the
crew follows, dragging the envelope over itself. Each person
drops a length of envelope into the bag, then returns to pick up
another armload. As the envelope goes into the bag, the amount
of fabric being handled gets lighter.
If the crown line is damp, remove it and store it outside the
bag. Secure the bag so the envelope will stay inside it.

Storage
When youreturn home withyour system, store everythingin
a cool, dry place. Place the envelope on stacked pallets soair can
circulate around it. Loosen the envelope bag and fluff up the
envelope so it is not tightlypacked, until the next time you load
it in your chase vehicle.