Balloon Owners Alert: Crack Checks Now Mandatory for Safety
Published Date: 10/10/2025
Rule
Summary
If you own or operate Cameron Balloons with certain fuel cylinders, listen up! The FAA is updating rules to keep you safe by requiring regular checks for cracks in pressure relief valve parts and, soon, replacing those parts to stop the checks. This new rule kicks in on October 27, 2025, so get ready to act and keep your balloons flying safely without surprise costs.
Analyzed Economic Effects
5 provisions identified: 1 benefits, 4 costs, 0 mixed.
Mandatory PRV adaptor replacement
You must replace the PRV adaptor with part number CB7922 as the terminating action for the repetitive visual checks. Replacement must be done either before further flight if any crack is found or at or before the next scheduled periodic PRV inspection.
FAA cost and scope estimates
The FAA estimates the AD affects 2,000 fuel cylinders worldwide and about 100 U.S.-registered hot air balloons. The FAA estimates a visual check costs 1 work-hour at $85 per check (cost per visual check $85; cost on U.S. operators per visual check $8,500) and replacement costs 2 work-hours ($170) plus $29 parts for a total of $199 per product (cost on U.S. operators $19,900).
Preflight crack checks required
If you operate a hot air balloon with a Cameron PRV adaptor P/N CB8426, you must visually check the fuel cylinder pressure relief valve (PRV) adaptor for cracks before further flight after October 27, 2025 and before each flight thereafter. If you find any crack, the fuel cylinder with the cracked PRV adaptor must be removed from service.
Pilots may perform checks; recordkeeping required
An owner/operator pilot holding at least a private pilot certificate may perform the required visual checks, and must record compliance in balloon maintenance records per 14 CFR 43.9(a) and 91.417(a)(2)(v). The FAA treats this as an exception to standard maintenance regulations.
Special flight permits banned
Special flight permits are prohibited under this AD, effective October 27, 2025. Operators cannot use special flight permits to move affected balloons for compliance or maintenance purposes under this rule.
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