APPENDIX II-A

FABRIC TEST METHODS

This document is FAA Approved as an appendix to the Airworthiness Limitations section of the Aerostar Continued Airworthiness Instructions (Reference Sections 3.0 & 5.1)

Approved by

Greg Michalik Chicago ACO

October 25, 2001

II-A-1 10/25/01

II-A.1.1 (1) Tell-tale

Envelope Testing

Inspect temperature "tell-tale" located in center, inside of top-cap. Fabric strength tests are required regardless of hours or age if the 275oF or higher dot has been activated. (2) Fabric (General) The condition of the fabric must be inspected at each Annual/100 hour inspection. During this inspection adequate fabric strength and porosity ratings are determined. Note Fabric strength tests MUST BE conducted unless the envelope is less than two years old and has less than 150 hours of total time logged. Tests MUST ALSO BE conducted regardless of time logged or age if: (1) An envelope "tell-tale" indicates that 275F has been exceeded: (2) The envelope shows signs of mold or mildew: (3) Increased fuel consumption has been noted: (3) Fabric Tests General: Several tests of the envelope fabric are required to determine the current and future airworthiness of the balloon. (a) Porosity: air leakage rate test of envelope fabric indicating condition of coating or tightness of weave of calendared fabric. *This test is performed at a differential pressure of 10" H20 in units of C.F.M. per sq. ft. See Appendix II-A, ABADS 1206.
* The lab machine is calibrated in accordance to the "Improved Instrument for Measuring the Air Permeability of Fabrics. Herbert F. Schiefer and Parl M. Boyland, National Bureau of Standards Research Paper PR1471, Journal of Research of National Bureau of Standards, Volume 28, pages 637-642, May 1942. Also reference Textile Test Method of Test for Air Permeability of Textile Fabrics A.S.T.M.; D737-46 and American Standards Association Standard, ASA No. L 14.51-1949."

(b)

"Grab" Tensile (Field Test): tensile test of envelope fabric across warp and fill yarns. This test is performed while fabric is in place. See Appendix II-A; ABADS 1096. "Tongue" Tear (Field Test): tear test of envelope fabric across warp and fill yarns. Requires removal of fabric in the test areas, and subsequent repair of tested areas. Detailed in Appendix II-A; ABADS 1205. 1" Tensile (Lab Test): tensile test of envelope fabric across warp and fill yarns. Fabric samples are removed and tested as covered
II-A-2 10/25/01

(c)

(d)

in Appendix II- A; Federal Test Method Standard 191b, Method 5012. (e) "Tongue" Tear (Lab Test): tear test of envelope fabric across warp and fill yarns. Fabric samples are removed and tested as covered in Appendix II-A; Federal Test Method Standard 191b, Method 5134.

(4) Key Test Areas The "flow-charts" of Figures II-A.1.A, B and C define the necessary testing of fabric in key areas. Fabric must be tested in each color and/or fabric type (i.e. Aerostar, Aeromax, and Aerolite) in all "key" areas. A key area is defined as each of the following areas of: (a) Deflation Panel testing should be performed beginning in stressed areas, such as adjacent to perimeter of the panel near the actuation line attaching point, or areas with visible heat damage: Upper Gore from the lower equator band to the port edge, begin testing the suspected weakest areas adjacent to port edge load tape and vertical load tape intersections. Test each color, in each fabric type, at the highest point in the main envelope; Other, areas (above the lower equator band) which appear to be damaged from heat, chemical attack, etc., where loss of fabric strength is suspected. In the event the envelope has been partially rebuilt or large areas of fabric have been replaced, testing must be accomplished on both the original and the new fabric as if it were different colors; NOTE ON KEY AREAS A key area, in which fabric has been replaced, should be treated in regards to the replacement fabrics respective hours logged and age. (5) Non-Key Areas Fabric below the lower equator circumferential band is considered to be a non-key area. However, non-key areas must be tested unless all of the following questions can be answered YES. 1. Are the test results in the key areas all greater then or = 35 lbs.?

(b)

(c)

II-A-3 10/25/01

2. 3.

Is the fabric below the equator of the same age, color and fabric type combinations as the key test areas? Does the fabric below the equator appear to be free from heat damage, chemical attack or other conditions that would make fabric strengths suspect?

If NO can be answered to any of the above questions the non-key areas must be tested as follows: (a) (b) Select one area of each color and/or fabric type near the lower equator circumferential band, and one area near the envelope base. Perform one Grab-Tensile in each area in both the warp and the fill directions to 35 lbs. as per ABADS 1096 (see appendix II-A).

Any failure of a color or fabric type in either area must lead to further identification of non-airworthy fabric at those locations. Refer to flow chart for proper procedures. EXAMPLE: An S-60A has blue & white vertical gores, a red top-cap and red equator between station's 60 & 44. In addition this envelope has Aeromax fabric starting at station 72.0 and continuing to the port edge. What areas require testing as a "keyareas"? ANSWER: 1. 2. 3. 4. 5. 6. Red Top Cap (Area A) Blue (Aeromax) at station 83.0 (Area B) Blue (Aerostar) at station 72.0 (Area B) White (Aeromax) at station 83.0 (Area B) White (Aerostar) at station 72.0 (Area B) Red Equator at STA 60 (Area B)

If porosity or strength is questionable in any key area, investigate more of the panel area of that color and location as well as other panels. Since an envelope will usually have one "lot" of fabric per color, one low strength panel would indicate the presence of other low strength panels in that color. EXAMPLE: An all blue S-55A, originally built in 1986 has been rebuilt at 425 hours 17 months ago from STA 62.75 to 72.75. The balloon now has 555 hours logged. What key areas are to be tested? ANSWER: All of the fabric above 62.75 has 130 hours logged and is less than 2 years old. As long as other conditions are met, this fabric is considered airworthy without further inspection. Fabric between 38.75 to 53.75 is considered a key area in addition to 53.75 to 62.75, therefore must be tested as well. Also, two grab tensile tests must be done (warp and fill) below 38.75, one near 38.75 and the other near the base, in each color.

II-A-4 10/25/01

(6) Flow Chart The Flow Charts of Figures II-A.1.A, B and C define the necessary testing of fabric in key areas. The Flow Chart is designed to simplify the qualification process with the Flow Chart symbols defined as follows: ---------------Entry point. Start here and follow the flowlines; Flow lines. Direction of arrow indicates path to next query block; Query block. This may contain any of several questions that may be answered by the appropriate testing. Conclusion block.

ENTER

PATH MAY BE CHOSEN.

------

(7) Testing To perform the fabric testing necessary to qualify the balloon for airworthiness, execute the following steps: Step 1: Enter and answer the appropriate questions. Step 2: Average of (3) sample areas in each color and/or fabric type in each key area, in accordance with ABADS 1206. If these values are greater than 75 CFM/ft sq., proceed to test areas toward the center of the panel or away from the stressed regions to determine how much of the panel is affected. Follow the flow line on the chart that corresponds to the porosity value determined in the above tests. 10% AREA REQUIREMENT: If the maximum porosity is exceeded in less than 10% of the panel area, answer this question YES. Note A panel is described as a region bordered on all sides by load tapes. Step 3: TENSILE AND TEAR TESTS: Strength testing is designed to determine whether sufficient strength (tensile and tear) is present to qualify the balloon as airworthy. The tensile and tear testing is set up in tiers as follows: (a) GRAB TENSILE (1): Perform one ABADS 1096, each, for warp and fill directions to either 45 lbs. (or 35 lbs.), depending upon which path is desired (Annual/100 hour or 50 hour retest) respectively. It is not necessary to pull to failure, only to the desired minimum value.
II-A-5 10/25/01

(b) GRAB TENSILE (5): Perform five ABADS 1096, each, for warp and fill directions, to 35 lbs. or 30 lbs. No single test may fall below 30 lbs. Follow the appropriate resultant flow-chart path. Tear tests, the final tier of testing, is designed to be used as the most discerning test of strength remaining in determining whether the balloon should be approved. All of this testing is subject to the factor played by the results of porosity testing. (c) TONGUE TEARS (1): Perform one ABADS 1205 tear tests, each, for warp and fill directions. No single test may fall below 3.7 lbs. Follow the appropriate flow-chart path. (d) TONGUE TEARS (5): Perform five ABADS 1205 tear tests, each, for warp and fill directions. No single test may fall below 2.5 lbs. or 1.75 lbs. as appropriate. Follow the appropriate flow-chart path Note Federal Test Method Standard 191b may be used in replacement of ABADS 1096 and 1205. Testing to 191b requires laboratory testing equipment and this testing must be performed only at Aerostars facilities and requires approximately 2 sq. ft. of fabric. Results of the testing will be sent to the repair facility along with a recommended approval/failure letter from the Maintenance Manager of Aerostar International, Inc.

Federal Test Method Standard 191b test criteria is as follows: FABRIC STRENGTHS
AIRWORTHINESS PERIOD ANOTHER YEAR OR 100 HOURS* ANOTHER YEAR OR 50 HOURS** 1" TENSILE EACH TEST MUST EXCEED 20 LBS. MINIMUM EACH TEST MUST EXCEED 20 LBS. MINIMUM TONGUE TEAR POROSITY

ALL TESTS EXCEED 2.5 LBS. ALL TESTS EXCEED 1.75 LBS

LESS THAN 50 CFM LESS THAN 75 CFM

II-A-6 10/25/01

Step 4: TESTING TERMINATION: Based on the testing results and the flow path followed on the Figure 5.1 Flow Charts, a final determination is reached as to the fitness of the fabric for continued airworthiness. The following is a description of various testing terminations and their results. -This key area has failed the inspection and is not airworthy for either 50 hour retest or Annual/100 hour. Proceed to the next key area for testing.

FAIL

PASS ANNUAL 50 HOUR

--

This key area is considered airworthy for Annual with a 50 hour retest, whichever comes first. Proceed to the next key area for testing.

PASS ANNUAL 100 HOUR

--

This key area is considered airworthy for Annual/100 hour, whichever comes first. Proceed to the next key area for testing.

NO FABRICT TESTS

--

If all preliminary questions can be answered "NO", then the envelope fabric may fore-go testing. It is considered airworthy for Annual/100 hour. NOTE FOR 50 HOUR RETESTING

Re-testing after 50 hours requires that the envelope fabric only be re-tested if the one year period has not expired, and the envelope has logged the additional 50 hours.

II-A-7 10/25/01

(8)

SPECIAL SHAPE/APPENDAGE BALLOONS

Fabric Testing (1) The external skin of the envelope, including any appendages, MUST be tested in accordance with the standard fabric test requirements. Perform the required tests in each color and/or fabric type, in the equivalent of each key and non-key areas. Pull tests must be performed in the upper areas of the main envelope and appendages. Perform fabric test in high stress areas of the envelope, areas where appendages are attached or where internal baffles attach to the main envelope. (2) The internal baffles and cantenaries MUST be tested as follows: (A) (B) No porosity testing required. Grab Tensile: Perform one ABADS 1096 test in each warp and fill direction of each color and/or fabric type, in the equivalent of each key and non-key area. Perform each test to 25 lbs. Note Any Internal baffle and cantenary fabric that fails the grab tensile test below 25 lbs. but above 20 lbs., must undergo additional testing per ABADS 1205, (Tongue Tear Test). (Tongue Tear Test): Remove two fabric samples, one in each warp and fill direction. Perform ABADS 1205 tongue tear tests. No test may fail below 1.75 lbs.

II-A-8 10/25/01

FIGURE IIA.1.A REQUIRED FABRIC TEST TEST FLOW CHART AEROSTAR COATED FABRIC

II-A-9 10/25/01

FIGURE IIA.1.B REQUIRED FABRIC TEST FLOW CHART AEROMAX AND AEROLITE COATED FABRIC

II-A-10 10/25/01

FIGURE 11A.1.C REQURED FABRIC TEST FLOW CHART CALENDARED FABRIC

II-A-11 10/25/01

(Intentionally Left Blank)

II-A-12 10/25/01

REVISIONS
LTR.
Orig. A All Para. 2.1; removed Five samples each. Para 2.2; change description of jaws including changing dimension of 1 x 2 to 1 or greater. Added Aerostar (Raven) wrench B-51406 as approved jaw. Para 2.4; Removed minimum force required. Figure 1; added depiction of Diamond weave.

DESCRIPTION

DATE
4/8/74 12/19/96

APPROVED
TAB

REV. STATUS OF SHEETS DRN. BY: CHD. BY: APPD. BY: DISTRIBUTION:

REV. SHEET INITIAL JMG

A
1

A
2

A
3 4 5 6 7 8 9 10 11 12 13 14 15 16

DATE 12/19/96

AEROSTAR INTERNATIONAL, INC.

E DRAWING NUMBER:

ABADS 1096

II-A-13 10/25/01

ABADS 1096 Hot Air Balloon Fabric Test Grab Method 1.0 Introduction

The following test procedure shall be used to verify the structural integrity of the balloon envelope fabric during the Annual/100 hour inspection. The intent of this procedure is to insure that the fabric has tensile properties commensurate with requirements imposed by structural loads during balloon operation. 2.0 Test Procedures

The procedure as outlined herein permits verification of balloon fabric without cutting or removing a test sample from the balloon envelope. The general test method, procedure, and results shall be comparable to that of Test Method 5100 of Federal Standard 191. 2.1 Samples shall be tested in both the warp (machine) and fill (transverse) directions. Sample locations shall be selected such that no two test samples contain the same warp yarns for warp direction tests nor the same fill yarns for tests in the fill direction. The test device shall provide two individual sets of jaws for clamping the balloon fabric. A method of securing or retaining one set of jaws, while applying a load to the second set, is required. Each clamping device shall be provided with one jaw having a dimension of 1" parallel to the application of the load and a dimension of 1" or greater perpendicular to the application of the load. The opposite jaw in each set shall measure 1" by 1" and shall be free to swivel in order to provide full surface contact when the jaws are closed. The jaws shall be faced with rubber or other material to prevent slippage and/or damage to the balloon fabric. AEROSTAR (Raven) modified locking wrench, P/N B-51406, is an approved clamping jaw. The tensile gauge utilized for this test shall be provided with a hold maximum indicator that retains the maximum load reading after load release until manual return to zero. Accuracy of the indicator shall be within + 3% up to a 50 lb. load. The balloon fabric shall be gripped as shown in Figure 1. Using the ripstop weave pattern as a guide, the jaws shall be positioned so that the same yarns, in the test direction, are gripped by both pairs of jaws. The distance between the clamps shall be 3". The grab test shall be accomplished by gripping the test gauge and applying a smooth, uniform pull force in the test direction. Care shall be taken to insure that the force is in line and parallel to the material sample within the jaws. The load as measured in 2.4 shall be recorded for each test in the warp direction and each test in the fill direction. The test results shall be the average of the number of tests performed in each direction if applicable.

2.2

2.3

2.4

2.5

II-A-14 10/25/01

RIPSTOP PATTERN (PARALLEL TO JAW EDGE)

3.0"

A
LOAD DIRECTION SQUARE WEAVE

SECTIO A- A N

RIPSTOP PATTERN (DIAGONAL TO JAW EDGE)

3.0"

A
LOAD DIRECTION DIAMOND WEAVE

SECTIO A- A N

II-A-15 10/25/01

REVISIONS
LTR.
Original All

DESCRIPTION

DATE

APPROVED

REV. STATUS OF SHEETS DRN. BY: CHD. BY: APPD. BY: DISTRIBUTION:

REV. SHEET INITIAL

3 4 5 6 7 8 9 10 11 12 13 14 15 16

DATE

AEROSTAR INTERNATIONAL, INC.

E DRAWING NUMBER:

Hot Air Balloon Fabric Test, Tongue Tear Strength

ABADS 1205
II-A-16 10/25/01

HOT AIR BALLOON FABRIC TEST, TONGUE TEAR STRENGTH 1.0 Introduction

The following test procedures shall be used to verify the tear strength of balloon envelope fabric during the Annual/100 hour inspection. It is the intent of this document to outline a procedure to insure that the fabric tear strength is adequate to withstand stresses imposed on the envelope during balloon operation. 2.0 Test Procedure

The procedure as outlined herein permits verification of the tear strength of fabric from an operational balloon by removing a small sample of fabric from the balloon in each color of the key area being tested. The basic test is a field test similar to Test Method 5134 of Federal Standard 191b. 2.1 Samples shall be tested in both the warp (machine) and fill (traverse) directions. Sample locations shall be selected such that no two test samples contain the same warp yarns for warp directions tests nor the same fill yarns for tests in the fill direction. The test device shall provide two individual sets of jaws for clamping the balloon fabric. A method of securing or retaining one set of jaws, while applying a load to the second set, is required. Each clamping device shall be provided with one jaw having a dimension of 1 or greater perpendicular to the application of the load. The opposite jaw in each set shall measure 1 by 1 and shall be free to swivel in order to provide full surface contact when the jaws are closed. The jaws shall be faced with rubber or other material to prevent slippage and/or damage to the balloon fabric. AEROSTAR (Raven) modified locking wrench, P/N B-51406, is an approved clamping jaw. Accuracy of the indicator shall be within 2% with the smallest increment of 0.1 lbs.+ 3% up to a 50 lb. Load. Remove a 4 x 6 inch sample of fabric from the key area to be tested. Divide the fabric sample into 2 x 4 inch individual test samples as depicted in Figure 1. Place a 1 1/2 inch slit in one end of each test sample to form two 1 x 1 1/2 tabs. The fabric shall be gripped as shown in Figure 2. The tear test shall be accomplished by gripping the test gauge and applying a smooth, uniform pull force in the test direction. Care shall be taken to insure that the force is in line and parallel to the material sample within the jaws. Refer to figure 5.1.A, B, or C for absolute minimum required test values. Note The force to be recorded is the peak force required to maintain the tearing motion. 2.5 The load measured in 2.4 shall be recorded for either one or five tests in the warp direction and either one or five tests in the fill direction, depending upon the number specified in the appropriate flow chart (figure 5.1.A, B or C).
II-A-17 10/25/01

2.2

2.3

2.4

6 4 1-1/2 SLIT 3 PLACES

FIGURE 1

FO RC E

FO RC E

II-A-18 10/25/01

FEDERAL TEST METHOD STANDARD 191b METHOD 5100 Strength and Elongation, Breaking of Woven Cloth; Grab Method 1. 1.1 2. 2.1 Scope This method is intended for determining the breaking strength and elongation of fabrics. Test Specimen The specimen shall be a rectangle of cloth 4" by not less than 6". The long dimension shall be parallel to the warp for warp tests and parallel to the filling for filling tests. No two specimens for warp test shall contain the same warp yarns, nor shall any two specimens for filling test contain the same filling yarns. The specimen shall be taken no nearer the selvage than 1/10 the width of the cloth. Apparatus A machine wherein the specimen is held between two clamps and strained by a uniform movement of the pulling clamp, the machine being operated in such a manner that the pulling clamp shall have a speed of 12 0.5 inches per minute. The design of each clamp shall be such that one gripping surface or jaw shall be an integral part of the rigid frame of the clamp, while the other shall be on a part hinged or swiveled to the movable member of the clamp. The face of one jaw of each clamp shall measure 1" by 1", and the other face of each jaw shall measure 1" by 1 or more inches with the long dimension perpendicular to the direction of application of the load. The distance between the clamps shall be 3" at the start of the test. The jaws shall have smooth gripping surfaces sufficiently flat and parallel to prevent slipping of the specimen during the test. All edges that might cause a cutting action shall be rounded to a radius of not over 1/64". In the case of rayon, nylon or other cloth of a slippery nature, the jaws may be faced with rubber or other material to prevent slippage. Dial, chart or scale to indicate applied tension. The indicator shall remain at the point of maximum load after failure of the specimen. Suitable autographic recording device when it is desired to measure elongation. The error of the machine at any reading within its loading range shall not exceed 2 percent up to and including a 50-pound load or 1% over a 50-pound load. The machine, when used for a given specimen, shall be of such capacity that the maximum load required to break the specimen is not greater than 85% or less than 15% of the rated capacity.
II-A-19 10/25/01

3. 3.1

3.1.1

3.1.1.1

3.1.2 3.1.3 3.1.4 3.1.5

3.2 4. 4.1

Means for applying an initial load of 6 ounces evenly across the width at the bottom of the specimen before gripping in the lower clamp of the machine. Procedure The specimen shall be placed symmetrically in the clamps of the machine with the long dimension parallel and the short dimension at right angles to the direction of application of the load. The yarn running parallel to the long dimension of the specimen shall be aligned parallel with one outside edge of the jaw of each clamp to insure the same yarns being gripped in both clamps. The tension on the yarns between the clamps shall be evenly distributed. Since the initial length and, therefore, the measured elongation depend upon the load applied in placing the specimen in the clamps of the machine, an initial load of 6 ounces distributed evenly across the width at the bottom of the specimen shall be placed on the specimen before gripping it in the lower clamp of the machine. The distance between clamps shall be 3" at the start of the test. Breaking -- Force shall be applied to the specimen at such a rate that the pulling clamp will travel at a uniform speed of 12 0.5" per minute. After rupture of the specimen, the breaking force shall be read from the dial, scale or chart and the value recorded. Elongation -- Elongation may be obtained when the breaking strength is determined and on the same specimen. Force shall be applied to the specimen as described in 4.4 and elongation determined by means of an autographic recording device on the testing machine. If a specimen slips between the jaws, breaks in or at the edges of the jaws, or if for any reason attributable to faulty technique, an individual measurement falls markedly below the average test result for the Unit-of-Product, such result shall be discarded and another specimen shall be tested. The elongation at the breaking point or other required load shall be expressed as the percent increase in length of the specimen held between the jaws and shall be obtained from the curve drawn on the graphic record. Report Unless otherwise specified in the material specification, five specimens from each of the warp and filling directions shall be tested from each Unit-of-Product. The breaking strength of the Unit-of-Products shall be the average of the results obtained from the specimens tested in each of the warp and filing directions and shall be reported separately to the nearest 1.0 pound. The elongation of the Unit-of-Products shall be the average of the results obtained from the specimens tested in each of the warp and filling directions and shall be reported separately to the nearest 1.0 percent.
II-A-20 10/25/01

4.2

4.3 4.4

4.5

4.6

4.7

5. 5.1 5.2

5.3

FEDERAL TEST METHOD STANDARD 191b METHOD 5012 Strength and Elongation, Breaking of Woven Cloth; Cloth Strip Method 1. 1.1 Scope This method is intended for determining the strip breaking strength of heavily sized, coated or other fabrics for which is impracticable to prepare a ravel strip specimen. Test Specimen The specimen shall be a rectangle of cloth 1" (or other width when specified) by not less than 6". No two specimens for warp test shall contain the same warp yarns, nor shall any two specimens for filling test contain the same fillings yarns. The specimen shall be taken no nearer the salvage than 1/10 the width of the cloth. Apparatus; Method Cited Apparatus Testing machine as described in Method 5100 except that when the width of the specimen is greater than 1", the long dimension of the jaws shall exceed the specimen width by at least 0.5". Method Cited Method 5100 Strength and Elongation, Breaking, of Woven Cloth Grab Method 4. 4.1 5. 5.1 Procedure The procedure shall be as described in Method 5100. Report The report shall be as described in Method 5100.

2. 2.1

3. 3.1 3.1.1

3.2

II-A-21 10/25/01

FEDERAL TEST METHOD STANDARD 191b METHOD 5134 Strength of Cloth, Tearing; Tongue Method 1. 1.1 2. 2.1 Scope This method is intended for determining the tearing strength of woven fabrics that have approximately the same tearing strength in both warp and filling directions. Test Specimen The specimen shall be a rectangle of cloth 3" by not less than 8". The short dimension shall be parallel to the warp for warp tests and parallel to the filling for filling tests. No two specimens for warp test shall contain the same warp yarns, nor shall any two specimens for filling test contain the same filling yarns. A 3" cut shall be made at the center and perpendicular to a short side of the specimen. The specimen shall be taken no nearer the salvage than 1/10 the width of the cloth. Apparatus; Methods Cited Apparatus Testing machine as described in Method 5100 except for the following: The face of the jaws shall measure 1" by 2 or more inches. All machine attachments for determining maximum loads shall be disengaged during this test. Methods Cited Method 5100 Strength and Elongation, Breaking of Woven Cloth Grab Method Method 5136 Strength of Cloth, Tearing Trapezoid Method 4. 4.1 Procedure The specimen shall be centered in the machine with one tongue of the specimen in each clamp. The machine shall be started and the force necessary to tear the cloth shall be observed by means of an autographic recording device. The speed of the pulling clamp shall be 12 inches 0.5 inch per minute.

3. 3.1 3.1.1 3.1.1.1 3.1.1.2 3.2

II-A-22 10/25/01

4.2

If a specimen slips between the jaws, breaks in or at the edges of the jaws, or if for any reason attributable to faulty technique, an individual measurement falls markedly below the average test result for the Unit-of-Product, such result shall be discarded and another specimen shall be tested. Calculation of Results -- Results shall be calculated as described in Method 5136. Report The report shall be as described in Method 5136.

4.3 5. 5.1

II-A-23 10/25/01

REVISIONS
LTR.
Original All

DESCRIPTION

DATE
10/24/01

APPROVED
MLW

REV. STATUS OF SHEETS DRN. BY: CHD. BY: APPD. BY: DISTRIBUTION:

REV. SHEET INITIAL JMG MLW MLW B, E

3 4 5 6 7 8 9 10 11 12 13 14 15 16

DATE 10/24/01 10/24/01 10/24/01 TITLE:

AEROSTAR INTERNATIONAL, INC.

DRAWING NUMBER:

ABADS - 1206

II-A-24 10/25/01

ABADS 1206 Hot air Balloon Fabric Test Field Porosity

1.0

Scope 1.1 This method covers the field determination of the air permeability of the nylon fabrics used in the manufacture of hot air balloon envelopes by Aerostar Intl., (Raven) under FAA Type Certificate A15CE, using the PX-1 field porosity testing machine, (Aerostar part number 52234).

2.0

Definitions 2.1 Air Permeability, n. The rate of flow of air through a fabric surface. Note 1 Air permeability is expressed in U.S. customary units as cubic feet of air per minute (c.f.m.) per square foot of fabric.

3.0

Summary Of Method 3.1 3.2 The rate of air passing through a known area of fabric in the test area and from this rate of flow the air permeability of the fabric is determined. Uses and Significance Air permeability is an important factor in the performance of the fabric as it relates to the overall performance of the aircraft. Air permeability is directly related to burner and fuel efficiency, a porous envelope will not respond as quickly to the operation of the burner and will also use the fuel on board in a shorter period of time. Air permeability can also be used to provide an indication of the future strength one can expect from the fabric.

4.0

Apparatus 4.1 The apparatus, PX-1, consists of a suction fan for drawing air through a known area of fabric defined by a circular orifice of diameter 2.75 in. (70 mm), and a means of measuring the rate of air flowing through the test area of the fabric. The fabric to be tested is placed over the screened opening of the testing machine. The PX-1 tests the porosity of the fabric at a differential pressure of 10 H2O in units of c.f.m. per sq. ft.

II-A-25 10/25/01

5.0

Sampling, Selection, and Number of Specimens 5.1 Testing is to be performed in each color and/or fabric type (i.e. Square Weave, Aerostar, Aeromax, Aerolite) in each key area of the envelope, as defined in section 5.1.1 of the ACAI. Begin testing in the high stressed areas of the panel, typically this will be near the intersection of the horizontal and vertical load tapes in the upper areas of the panel. Perform tests in three sample areas horizontally across the panel and average the results. This average will be the porosity rating for that test area. Additional testing of the panel at various positions may be necessary to determine the overall condition of the panel.

A minimum of one test must be performed in each color and/or fabric type in each key area. One test consists of three sample areas averaged together to determine the porosity of the area. If fabric in other key areas of the envelope are suspected of having increased porosity from chemical attack, overheating or other abuse, those areas must be tested to determine the airworthiness of the fabric. 6.0 Procedure 6.1 Calibrate the PX-1 porosity tester using the calibration plate as outlined in the PX-1 operating Instructions manual. Additional calibration checks should be performed on the PX-1 when operating the machine for extended periods of time as detailed in the PX-1 Instructions Manual. Place the sample to be tested over the opening of the porosity tester insuring that the sample fits tight and smooth over the opening. Wrinkling of the fabric may allow additional air to pass through the PX-1 resulting in an invalid test reading. Perform the tests in the three sample areas horizontally across the panel of the area being tested. Record the result as indicated on the PX-1 gauge of the three sample areas. Calculate the average porosity of the three sample areas.

6.2

6.3 6.4 6.5

II-A-26 10/25/01