FAA proposes easing pilot oxygen mask rules; insurers may not follow

The FAA has proposed loosening oxygen mask rules that date to 1961 and 1970 that call for one pilot to always be wearing a mask at high altitude on certain Part 91 and Part 135 operations. Operators flying high-altitude missions have built that procedure into normal cockpit operations ever since. The new proposal could materially alter that status quo. In the proposal, published Sept. 24, the FAA would raise the altitudes at which a pilot must don an oxygen mask for commuter and on-demand operations, and revise the requirements for general aviation operations in pressurized aircraft. The proposal will not wholly eliminate oxygen equipment requirements, but changes when pilots would be required to wear the equipment. For Part 135, the proposal moves the mask requirement from above 35,000 feet to above FL410 for two-pilot operations, and from above 25,000 feet to above FL350 for single-pilot operations. For Part 91, it keeps the quick-donning mask condition but drops the FL410 cap. An airplane equipped with quick-donning masks at both pilot positions would have no altitude ceiling on the exemption. Congress directed the proposal in part through Section 834 of the FAA Reauthorization Act of 2024 with comments due Nov.23, 2026. The NBAA has backed it strongly. "NBAA has long been an advocate for ensuring regulations evolve with technology advancements," said Heidi Williams, NBAA senior VP of operations. "The association is pleased to see its years-long advocacy bear fruit in the recent proposed rule." The FAA says these changes would reduce regulatory and economic burdens on operators, estimating a savings of between $4.7 million and $18.6 million a year in oxygen servicing fees (based on refills costing between $100 and $400). Why it matters If adopted, operators' own policies may not change alongside the law. Many insurers, flight departments, and safety-management systems maintain standards that go beyond FAA minimums. While some may welcome the change, others may keep existing mask-use policies because insurers, company standards or risk-management programs continue to favor them. That means the practical impact could vary from one operator to another and will depend as much on insurer requirements and company policies as on the FAA's final rulemaking decision.