A hot-air balloon in flight, 2021: the basket hangs below the open mouth, the burner between them.Hot air balloon IMGP0344a · 2021-09-12 18:01:49 · Alexey V. Kurochkin · CC BY-SA 4.0 · Commons ↗
A balloon lifts by weighing less than the air it pushes aside. The Montgolfier brothers flew a hot-air balloon 10 m across, with nobody aboard, at Annonay on 4 June 1783; on 21 November two men flew for 25 minutes and about 9 km over Paris (Linda Hall Library). Balloons are still at work: weather balloons are launched twice a day from nearly 900 sites (NOAA), and tethered balloons lift observers, aerials and cameras. They also kill in ways that are known in advance: hydrogen burns, and power lines killed all 16 aboard a hot-air balloon in Texas in 2016 (NTSB).
The shape of it
Work out the lift: volume × the lift per cubic metre of the gas at its temperature.
Build the envelope from gores, sealed at every seam.
Hot air: heat on the ground where you can; keep flame and sparks away from the fabric.
Hydrogen: make it outdoors from iron and acid, with no flame or spark anywhere near.
Tether with a line and winch, in calm air, away from power lines.
Use it: observation, signals, aerials, and small balloons to measure the wind aloft.
What one cubic metre liftsFig 1
Loose fill / grainFire / hot zone
At sea level in air at 15 °C: hot air at 100 °C lifts 0.28 kg, at 120 °C 0.33 kg; helium 1.06 kg; hydrogen 1.14 kg, and it burns.
Doing it, step by step
The summary above says what has to happen. This says how, with the numbers that decide whether it works.
1 — Lift, per cubic metre
Air at 15 °C weighs 1.225 kg a cubic metre at sea level. A balloon lifts that weight minus the weight of the gas inside:
Hot air at 100 °C weighs about 0.95 kg/m³, so each cubic metre lifts 0.28 kg; at 120 °C, 0.33 kg.
Helium lifts 1.06 kg/m³; hydrogen1.14 kg/m³.
Height and heat cut lift: at 2,000 m the air is thinner and every figure is about 18 % less; on a hot day, a hot-air balloon lifts less.
Worked example: a person of 80 kg with a light basket and envelope, 230 kg in all, needs about 820 m³ of air at 100 °C: a sphere about 11.6 m across.
✓ Check: You can compute the volume a load needs at a given temperature, and have measured a model's lift with a spring balance.
2 — Hot air
The Montgolfiers' first balloon, in June 1783, was 10 m across, of cloth lined with paper, and filled over a fire on the ground; it rose between 1,600 and 2,000 m and stayed up 10 minutes (Linda Hall Library). The first people to fly carried their fire with them. Today's balloons carry propane burners and fly in calm air near dawn and dusk.
An envelope of gores, each tapering to the crown, sealed at every seam.
Heat-resistant fabric at the mouth, where the heat is fiercest (Cameron Balloons).
Keep flame and sparks off the fabric: paper and cotton burn, and so does nylon.
A burner driving hot air into the open mouth of a hot-air balloon lying on its side, before it stands up.Flame.inflates.balloon.bath.arp · Taken on 21 September 2005 (ac · Arpingstone · Public domain · Commons ↗Inside a hot-air balloon's envelope, looking up: the gores meet at the crown, each sewn from panels.Inside of a hot air balloon · 2022-07-01 06:52:05 · Hu Nhu · CC BY-SA 4.0 · Commons ↗A hot-air balloon in flight, 2021: the basket hangs below the open mouth, the burner between them.Hot air balloon IMGP0344a · 2021-09-12 18:01:49 · Alexey V. Kurochkin · CC BY-SA 4.0 · Commons ↗
✓ Check: The envelope has been filled over a heat source that stays on the ground, and its lift measured before any load is tried.
3 — Hydrogen: four times the lift, and it burns
Hydrogen lifts about four times what hot air does, cold, for as long as the envelope holds it. It is made from iron and dilute sulphuric acid (acid): Fe + H₂SO₄ → FeSO₄ + H₂, about 0.4 m³ of hydrogen for every kilogram of iron dissolved.
It burns in air at any mixture from 4 % to 74 %, and a spark of 0.02 mJ — far less than a static spark from clothing — lights it (US DOE).
Make and fill it outdoors, with no flame, no smoking, and no one in wool or synthetic clothing near.
Helium lifts nearly as much and does not burn, but it comes from natural gas wells, which is a later tier.
✓ Check: Hydrogen is made and handled only outdoors, with no flame or spark source within the working area.
4 — Tethered: observation, signals and aerials
A tethered balloon holds a position above the ground: an observer's eye, a signal lamp, or an aerial. Armies used tethered balloons for observation through the First World War; the US Army's 1918 manual covers the work (Balloon observation).
A winch to haul down, and a cable rated for the lift plus the wind's pull.
Calm air only: wind blows a tethered balloon down and over, and it drags.
The same airspace rules as a large kite: in the US, no higher than 500 ft and no nearer than 5 miles to an airport (14 CFR 101.13).
A tethered passenger balloon over Tallinn, 2015, from below: the gondola hangs from a net over the envelope, held by one cable to a winch.Tallinn Tethered Balloon from below 2015 · 2015-07-29 · Cayambe · CC BY-SA 4.0 · Commons ↗
✓ Check: The tether and winch are rated for lift plus wind load, and the balloon is flown only in calm air within the height allowed.
5 — Weather balloons
Every day at 00:00 and 12:00 UTC, weather services release balloons from nearly 900 sites; each lifts a radiosonde that radios back temperature, humidity and pressure, and is tracked for the wind (NOAA). A rebuilding community can do the simplest version: a small gas balloon followed by eye through a theodolite gives the wind at each height it passes.
Releasing a weather balloon, 2021: the instrument hanging below radios back temperature, humidity and pressure as it climbs.Radiosondes launch · 2021-08-25 · Tsaud · CC BY-SA 4.0 · Commons ↗
✓ Check: A balloon ascent has been timed and followed, and the wind aloft worked out from its drift.
6 — Where balloons kill
Power lines: a hot-air balloon struck power lines near Lockhart, Texas, on 30 July 2016 and all 16 aboard died (NTSB). Every launch and landing field is checked for lines first.
Fire: never release a hot-air balloon with a flame aboard. Brazil makes making, selling or releasing balloons that can start fires a crime, with one to three years' detention (Law 9.605/1998, art. 42).
Weather: a balloon goes where the wind goes; it cannot steer away from anything.
People who fly in a balloon learn from an instructor first: the FAA's Balloon Flying Handbook is the standard text.
✓ Check: No launch site has a power line within the tether's length, and no flame is ever released.
What it looks like
A burner driving hot air into the open mouth of a hot-air balloon lying on its side, before it stands up.Flame.inflates.balloon.bath.arp · Taken on 21 September 2005 (ac · Arpingstone · Public domain · Commons ↗A tethered passenger balloon over Tallinn, 2015, from below: the gondola hangs from a net over the envelope, held by one cable to a winch.Tallinn Tethered Balloon from below 2015 · 2015-07-29 · Cayambe · CC BY-SA 4.0 · Commons ↗Releasing a weather balloon, 2021: the instrument hanging below radios back temperature, humidity and pressure as it climbs.Radiosondes launch · 2021-08-25 · Tsaud · CC BY-SA 4.0 · Commons ↗Inside a hot-air balloon's envelope, looking up: the gores meet at the crown, each sewn from panels.Inside of a hot air balloon · 2022-07-01 06:52:05 · Hu Nhu · CC BY-SA 4.0 · Commons ↗
Build it
Dimensioned drawings, bills of materials and construction procedures for the things this step asks for.
What the record shows was done at this step, what to do instead at this tier, and the evidence. All of them: the better path.
Do not repeat
Fire balloons released free
What was done
Paper balloons lifted by a burning wick and released free, at festivals and celebrations, from the 18th century to today.
Do instead
Tether every hot-air model and keep the heat on the ground; never let a flame fly.
Evidence
They land burning wherever the wind takes them. Brazil made making, selling, transporting or releasing balloons that can start fires a crime in 1998, with one to three years' detention (Law 9.605/1998, art. 42).
Needs nothing that is not already in hand.
How this fails
Flying into power lines, which killed all 16 aboard a balloon at Lockhart, Texas, in 2016.
Hydrogen near a flame or a static spark.
A hot-air model released free with a flame aboard: a fire started wherever it lands.
Tethering in wind: the balloon is blown down and over and the envelope tears.
Forgetting that lift falls with height and with warm weather.
How you know it worked
VerificationThe lift of the balloon has been measured with a spring balance and agrees with volume × lift per cubic metre; it has flown tethered, in calm air, with nothing within its tether's length of a power line; and no flame has flown free.