SPECIAL FLIGHT PERMITS (SFP) - AUSTRALIA GUIDE
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QUICK ANSWER: WHAT IS A SPECIAL FLIGHT PERMIT:
A Special Flight Permit (SFP) is temporary authorisation from CASA, or a CASA Authorised Person, that allows an aircraft to fly even when it doesn't meet normal airworthiness requirements. It's issued for specific purposes like ferry flights to maintenance facilities, new aircraft delivery, or emergency evacuations. The permit is only valid for the flights and timeframe needed for the purpose.
WHAT IS AN SFP?
Aircraft don't always stay airworthy. Maintenance expires, unexpected defects arise, or you need to move an aircraft that isn't quite ready to fly under normal rules. When this happens in Australia, a Special Flight Permit (SFP) may be the solution, and it's more common than you might think.
Whether you're ferrying an aircraft to maintenance in Queensland, delivering a newly purchased plane to Adelaide, repositioning before a bushfire threatens your hangar, or a flood covers the runway, a Special Flight Permit gives you the legal authority to fly when standard airworthiness requirements aren't fully met.
Think of it as a temporary flight pass. Under Part 21 of the Civil Aviation Safety Regulations (CASR), an SFP lets you legally operate an aircraft that's capable of safe flight for your specific purpose, even if it doesn't tick every airworthiness box.
Important: This isn't a free pass to fly however you want. Every SFP comes with strict conditions - route restrictions, weather requirements, crew qualifications, weight limits, passenger restrictions, among others - tailored to keep your specific flight safe.
QUICK ANSWER: WHO CAN ISSUE AN SFP
In Australia there are two legal pathways to issue a Special Flight Permit:
CASA (Civil Aviation Safety Authority): Full authority for all SFP purposes.
Authorised Persons (CASA Delegates): Can assess and issue SFPs within their delegated scope.
WHO CAN ISSUE A SPECIAL FLIGHT PERMIT IN AUSTRALIA?
CASA isn’t the only source. There are two groups that can legally issue a Special Flight Permit in Australia:
CASA (Civil Aviation Safety Authority): The national regulator processes all SFP applications submitted directly to them. CASA has full power for SFP purposes.
Authorised Persons (CASA Delegates): Certain organisations and individuals authorised by CASA to assess and issue special flight permits within their scope of authority. (CASA doesn’t give full power to Authorised Persons, but even with these restrictions Authorised Persons typically issue the bulk of SFPs in Australia).
CASA DIRECT VS USING AN AUTHORISED PERSON
If you submit to CASA, the application typically passes through admin steps (including a fee estimate) before an inspector starts the technical assessment; timing varies depending on completeness, complexity, and time of submission (within or outside of business hours).
If you apply through an Authorised Person, (sometimes referred to as a CASR 21.200 authorised person), they can assess, set limitations, and issue the permit when satisfied the aircraft is capable of safe flight for the intended purpose, within their authority. Direen Aviation’s scope includes maintenance repositioning flights.
QUICK ANSWER: WHEN DO YOU NEED A SPECIAL FLIGHT PERMIT?
You need a Special Flight Permit (SFP) when your aircraft can’t legally fly under normal airworthiness requirements (for example, because of an expired maintenance release, an unrectified defect, or an out-of-limits condition), but it’s still capable of safe flight for a specific, permitted purpose under strict limitations (route, weather, crew, weight, etc.)
THE SEVEN APPROVED PURPOSES (CASR 21.197)
If the flight doesn’t fit one of these purposes, CASA (or an Authorised Person) can’t issue an SFP
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The official CASA language: CASR 21.197(1)(a)Flying the aircraft to a base where repairs, alterations, or maintenance are to be performed, or to a point of storage.
Scenario: Your aircraft is grounded, for example, at a remote airstrip in outback Queensland. The maintenance release has expired, or a defect has been found that can't be fixed on-site. You need to ferry it to a maintenance facility in Brisbane.
Why you need an SFP: The aircraft doesn't currently meet dispatch requirements, but a one-time repositioning flight to your maintenance base is safe and practical.
What Direen Aviation does: Our CASA delegates conduct a detailed airworthiness assessment, confirm the aircraft is suitable for a maintenance repositioning flight, and issue a special flight permit with clear conditions appropriate for the flight for safe arrival at your maintenance facility.
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The official CASA language: CASR 21.197(1)(b)Delivering or exporting the aircraft
Scenario: An SFP may authorise a one-off delivery flight for a new production aircraft from a factory or dealer to the operator’s base or nominated maintenance facility, where the aircraft is safe to fly but is still pending final configuration, inspections and documentation required before it can operate under a Certificate of Airworthiness.
Why you need an SFP: To legally conduct that specific delivery flight under defined operating limitations when the aircraft isn’t yet eligible for normal service. It allows you to reposition the aircraft to the place where final configuration, inspections and compliance steps can be completed before the Certificate of Airworthiness is issued.
Note on exporting and importing: An Australian SFP is generally limited to operations in Australian territory. Exporting or importing may also require overflight and landing permissions (and any additional requirements) from the relevant National Aviation Authorities for the countries whose airspace you intend to enter or overfly.
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The official CASA language: CASR 21.197(1)(c) Production flight testing new production aircraft.
Scenario: Aircraft manufacturers (and parties directly tied to the manufacturer or production approval) may use an SFP to conduct a defined production test flight or short series of flights on a newly manufactured aircraft before it can be issued with Certificate of Airworthiness.
In plain terms, the aircraft may be “new”, but it’s not yet eligible for normal service because the final production certification process isn’t complete, and CASA uses the SFP framework to allow the flight only under controlled conditions.
Why you need an SFP: Because the aircraft may not currently meet applicable airworthiness requirements but can still be reasonably expected to be capable of safe flight for the intended purpose if the operation is restricted. That’s the whole philosophy of an SFP: permit a specific purpose, then control risk through conditions and limitations.
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The official CASA language: CASR 21.197(1)(d) Evacuating the aircraft from areas of impending danger.
Scenario: Cyclones, bushfires, floods, severe storms, rising water, or other time-critical threats can put an aircraft at real risk of loss or significant damage while it’s parked and unable to operate under normal airworthiness requirements.
In these situations, an SFP may allow a one-off evacuation (repositioning) flight to move the aircraft to a safer aerodrome or storage location even if maintenance is overdue or defects exist, provided the aircraft is still capable of safe flight for that specific operation and the flight is conducted under defined operating limitations.
Why you need an SFP: Because evacuation flights often happen when the aircraft may not currently meet all applicable airworthiness requirements, but can still be operated safely for a limited, specific purpose if the operation is restricted to match the aircraft’s reduced capability.
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The official CASA language: CASR 21.197(1)(e) conducting customer demonstration flights in new production aircraft that have satisfactorily completed production flight tests.
Scenario: This purpose exists to allow sales or pre-delivery demonstration flights in a new production aircraftafter the aircraft has satisfactorily completed its production flight tests, but before it is issued with a Certificate of Airworthiness (or while it is otherwise not eligible for normal service).
Why you need an SFP: A demo flight can be safe and reasonable, but if the aircraft isn’t yet operating under its Certificate of Airworthiness, it can’t be flown in normal service. An SFP provides the legal pathway to conduct that demonstration flight under specific conditions and limitations until certification steps are finalised.
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The official CASA language: CASR 21.197(1)(f) assisting in searching for, bringing aid to or rescuing persons in danger on a particular occasion.
Scenario: This purpose is aimed at one-off, urgent missions where an aircraft is needed to help locate, support, or recover people in danger, for example:
- flying medical supplies, rescue equipment, or essential personnel into an isolated area;
- assisting with an aerial search;
- extracting people from a remote location where time is critical.
The key is that the mission is time-sensitive and tied to a particular occasion, not routine operations.
Why you need an SFP: Because in genuine emergency deployments the aircraft might not fully meet normal airworthiness requirements at that moment (e.g., maintenance overdue, a defect that would normally prevent dispatch), but it may still be safe to operate for this limited purpose if appropriate operating limitations are applied that keep risk acceptable. The SFP is the legal mechanism CASA uses to authorise that specific flight with explicit conditions.
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The official CASA language: CASR 21.197(1)(g) assisting in dealing with a state of emergency.
Scenario: This purpose is broader than search and rescue. It applies where an officially declared state of emergency is driving urgent aviation activity, for example:
- emergency management support and coordination,
- critical logistics (moving essential supplies, specialist personnel, communications equipment),
- support flights to enable response activity in areas impacted by fire, flood, cyclone, or other declared events.
In these situations, an aircraft may need to operate for the emergency response purpose even though it may not currently meet all applicable airworthiness requirements, provided it is still capable of safe flight for the intended operation under defined operating limitations.
Why you need an SFP: Not “because it’s urgent”, but because a declared emergency can create a legitimate need for an aircraft to fly for a specific response task at a time when it may be temporarily non-compliant, and the SFP is CASA’s legal mechanism to:
- confirm the state of emergency is officially declared,
- confirm the aircraft is specifically required for the response (not just convenient), and
- authorise the operation only under stated conditions that reduce risk to an acceptable level for the particular mission.
A NOTE ON OVERWEIGHT FLIGHTS
While “overweight” is not listed as a standalone purpose in CASR 21.197(1), an SFP may authorise an aircraft to operate above its maximum certificated take-off weight when that excess weight is attributable to additional fuel, ferry fuel installations, and equipment added for a specific flight beyond the aircraft’s normal range. This is common for long-range ferry flights (for example, USA to Australia deliveries) where temporary ferry tanks and associated equipment can push the aircraft above its normal maximum take-off weight (MTOW).
The 110% MTOW threshold (how CASA treats it):
CASA guidance highlights a key threshold at 110% of certificated MTOW:
If the proposed MTOW exceeds 110%, CASA expects additional substantiation with the application, including an engineering evaluation of structural loads (and CG effects) and evidence (by flight test or other acceptable means) that performance and handling remain satisfactory in the overweight condition.
CASA’s guidance also notes that if the type certificate holder or the NAA of the State of Design supports the overweight operation in writing, no further engineering evaluation is required.
(Practically, 110% is a “step up” point in scrutiny, and written support from the design authority can be decisive.)
What's required: For an overweight ferry SFP, CASA typically expects approved ferry tank installation data plus the operational information needed to safely fly overweight, such as weight and balance, fuel system procedures, overweight performance limits, and any flight profile restrictions.
For CASA’s guidance on overweight SFP expectations and substantiation, see AC 21-09.
WHEN YOU MIGHT NOT NEED A SPECIAL FLIGHT PERMIT (SFP VS MEL)
Not every defect grounds an aircraft. Many items can be deferred under an approved Minimum Equipment List (MEL) or managed through maintenance release processes.
QUICK ANSWER: SFP VS MEL
Minimum Equipment List (MEL): Allows you to dispatch with specific inoperative items under defined procedures. Aircraft remains compliant with airworthiness standards.
Special Flight Permit: Authorises flight when the aircraft doesn't meet airworthiness requirements but is capable of safe flight for a specific purpose, with restrictions like route, weather, or passenger limits.
HOW TO APPLY FOR A SPECIAL FLIGHT PERMIT (STEP BY STEP)
Step 1: Confirm You Need a Permit
Before filling out forms, verify that an SFP is actually required and that your planned operation fits one of the seven approved purposes:
Flying to a base for repairs, alterations, maintenance or storage
Delivering or exporting the aircraft
Production flight testing of new production aircraft
Evacuating aircraft from areas of impending danger
Customer demonstration flights in new production aircraft
Searching for, bringing aid to, or rescuing persons in danger
Assisting in dealing with a state of emergency
If you're unsure, contact a CASA delegate like Direen Aviation for a quick consultation.
STEP 2: CHOOSE YOUR APPROVAL PATHWAY
For maintenance ferry flights: Submit directly to an Authorised Person (like Direen Aviation) for faster processing.
For other purposes: You may need to apply through CASA using Form 725, especially for complex operations like international delivery or search and rescue.
STEP 3: DEFINE YOUR FLIGHT SCOPE
Be specific. CASA and Authorised Persons prefer tightly scoped applications:
Limited number of flights (ideally one to three)
Specific route with alternates identified
Clear dates and duration
Defined purpose (e.g., 'Ferry from Bundaberg to Sunshine Coast for 100-hour inspection')
Avoid open-ended requests. Broad itineraries expand risk and raise red flags. Keep it tight and purposeful.
STEP 4: PREPARE YOUR AIRCRAFT CONDITION SUMMARY
This is where you explain why the aircraft doesn't meet normal requirements and how it can still fly safely. Include:
Aircraft type, registration, and current configuration
What's unserviceable or overdue (e.g., 'Maintenance release expired 3 days ago')
What inspections and maintenance checks have been completed
Why the flight is safe (e.g., 'Day VFR flight only,' 'No passengers,' 'Direct route with alternates')
STEP 5: GATHER SUPPORTING EVIDENCE
A complete evidence pack reduces back-and-forth and speeds up assessment. The exact requirements depend on the SFP purpose, but typical supporting documents include:
Aircraft status / maintenance evidence
Maintenance Release and/or relevant tech log entries
List of open/deferred defects (including MEL items where applicable) and how the proposed flight will be safely managed
AD compliance status, including any outstanding actions (if applicable)
Operational history (last flight date, preservation details, engine runs/ground checks if recently inactive)
Technical substantiation (where needed)
OEM / Type Certificate Holder support (e.g., engineering assessment or “no technical objection”)
Weight and balance calculations (especially for ferry configurations and overweight operations)
Engineering orders / approved data for temporary modifications (e.g., ferry fuel systems)
Operational plan
Proposed route and dates, including alternates and contingencies
Crew
Crew qualifications (licences, ratings, currency/recent experience)
STEP 6: PURPOSE AND CONDITIONS
Special Flight Permits are issued with written conditions and limitations tailored to the specific flight and the aircraft’s status. Depending on the purpose, these may cover:
Operating rules / weather minima (e.g., “day VFR only”; case-specific restrictions such as “VMC while operating above MTOW”)
Route, area and altitude constraints (defined route or area of operations, nominated alternates, and any airspace or altitude restrictions needed for safety)
Crew requirements (e.g., minimum crew, currency and experience requirements, and where appropriate instrument-rated pilots)
Persons on board (often “essential crew only”; restrictions on passengers or non-essential personnel)
Weight and loading limits (maximum take-off weight, CG loading requirements, and any overweight limits supported by the application data)
Configuration and defect related limits (restrictions tied to the actual defects or temporary modifications, what you can’t do, and why)
Pre-flight and ongoing checks (e.g., inspections of temporary installations such as ferry fuel systems, and any required checks between legs)
STEP 7: SUBMIT YOUR APPLICATION
To CASA: Use CASA Form 725.
To an Authorised Person: Contact them directly (e.g., Direen Aviation for maintenance repositioning flights).
Once approved, you'll receive the permit with conditions attached. You must carry the permit on board during the flight and place it in the aircraft's permanent airworthiness records afterwards.
Tip: Prefil the form, one for each aircraft in your fleet, and save it in a readily accessible location. Your application will be ready much quicker when time is critical.
WHAT ‘CAPABLE OF SAFE FLIGHT’ ACTUALLY MEANS
The cornerstone of every SFP is proving your aircraft can reasonably be expected to be capable of safe flight for the intended purpose. That’s straight from CASR 21.197.
Here's what it means in practice:
1. Safety Case
You need to show that known defects or non-compliances are controlled and that the aircraft's performance is sufficient for the specific flight. For instance, if you're ferrying overweight with extra fuel, your weight and balance calculations, fuel system engineering approval, and performance analysis must demonstrate safe operation.
2. Tailored Limitations
Tailored SFP limitations aren’t generic rules, they’re the specific, measurable controls that make a one-off flight acceptable by bounding the risk. In practice they typically restrict who can be carried and what the flight can be used for, constrain the route and operating environment, require all unrelated equipment to be serviceable (or properly deferred under the MEL), mandate disciplined inspections and flight planning, impose configuration and handling limits for the highest risk phases of flight, and ensure everything is recorded in the tech log and aircraft records.
3. Capable Crew
CASA wants assurance that your crew has the competence to manage abnormal situations. Instrument ratings, type ratings, currency, and experience are often specified as permit conditions.
4. Propose clear risk controls
Propose clear risk controls that make the flight acceptably safe for the intended purpose. Define the route and alternates, weather minima (e.g., Day VFR only), weight and configuration limits, and exactly who will be on board as essential crew. Then document any equipment restrictions, required checks, and contingency actions so the assessor can clearly see how risk is being managed.
QUICK ANSWER: DOES AN SFP ALLOW INTERNATIONAL FLIGHT?
No. An Australian SFP is valid only within Australian jurisdiction. For international ferry flights, you must obtain separate authorisations from each country you'll overfly or land in. Plan early, processing can take weeks and align your SFP validity period with foreign permit timelines.
INTERNATIONAL FERRY FLIGHTS: UNDERSTANDING CROSS BORDER PERMISSIONS
Critical point: An Australian Special Flight Permit does not authorise you to fly over or land in other countries. Every country you'll overfly or land in requires a separate authorisation.
For international ferry flights (e.g., Australia to the United States), you must:
Obtain an Australian SFP for the Australian leg
Apply for overflight and landing permits from each country along the route (e.g., Papua New Guinea, Solomon Islands, Fiji, United States)
Allow sufficient lead time; official processing times vary from country to country but can extend to weeks rather than days.
Planning tip: Map your entire route early, identify every country whose airspace you'll enter, research their permit requirements, and apply well in advance. If you're using an Authorised Person for your Australian SFP, they may be able to assist with coordinating foreign approvals or connect you with ferry flight specialists.
QUICK ANSWER: WHY USE A CASA AUTHORISED PERSON
Using a CASA Authorised Person dramatically reduces approval time, vs going to CASA direct. Authorised Persons like Direen Aviation have authority to issue permits within their scope, understand the regulatory requirements intimately, and can tailor conditions to suit both safety and operational needs. For time critical maintenance ferry flights, Authorised Persons are often the fastest path to getting your aircraft airborne.
Frequently Asked Questions ABOUT SPECIAL FLIGHT PERMITS
Still have questions? Take a look at the FAQ or reach out anytime. If you’re feeling ready, go ahead and apply.
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Usually yes if the aircraft doesn’t meet applicable requirements (e.g., expired maintenance release or defect preventing dispatch). But if you can legally operate under the MEL and maintenance release for the intended flight, an SFP may not be required.
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Yes for eligible cases within scope: Direen Aviation has CASA Authorised Persons who can assess and issue SFPs for maintenance repositioning flights within Australia.
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Any person may apply (typically it’s the registered operator). CASA applications use Form 725; Authorised Person applications go direct to the delegate.
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Yes - carry it for the flight(s) and then file it in the permanent airworthiness records.
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No. Separate approvals are required for each country.
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No. A Special Flight Permit is temporary authorisation for specific flights only. It does not replace a Certificate of Airworthiness or allow normal commercial operations. The permit expires when the specified period ends.
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The application should include: purpose of the flight, aircraft details (type, registration, configuration), defects and maintenance status, proposed route and itinerary, weight and balance calculations (especially for overweight operations), engineering approvals (if applicable), crew qualifications, and draft conditions.