The air transport of batteries requires strict compliance with IATA (International Air Transport Association) regulations. These regulations are essential for air transport safety, as batteries can pose a fire or explosion risk under certain circumstances. The IATA has established specific protocols for classification, packaging, labelling, documentation and training. In this article, we discuss the mandatory regulations for the air transport of batteries, so that you know exactly what you need to comply with.
The IATA stipulates that all batteries transported by air must comply with the regulations for dangerous goods. This means that batteries are classified as dangerous goods within Class 9 (miscellaneous dangerous goods). The basic requirements comprise three main elements: correct classification, safe packaging and proper documentation.
For classification, batteries must be identified according to their chemical composition and form (cell or battery pack). Each battery type has a specific UN number and packing instruction. Regarding packaging, batteries must be protected against short-circuiting, damage and accidental activation during transport. The documentation must contain all relevant information, such as the battery type, UN number and packing instructions.
In addition, it is important that staff involved in the dispatch of batteries have received the appropriate training. IATA requires that all staff involved in the preparation or handling of shipments containing dangerous goods, including batteries, hold certification in accordance with the DGR (Dangerous Goods Regulations).
IATA distinguishes between different battery types, each with its own regulations and packaging requirements. The most common categories are lithium-ion batteries, lithium-metal batteries and non-lithium batteries.
Lithium-ion batteries (UN3480 for loose batteries, UN3481 for batteries in equipment) are used in many portable electronic devices such as laptops, smartphones and drones. These batteries have specific packaging instructions (PI965 for loose batteries, PI966 for batteries packed with equipment, PI967 for batteries in equipment).
Lithium metal batteries (UN3090 for loose batteries, UN3091 for batteries in equipment) are non-rechargeable batteries often used in medical equipment, remote controls and watches. These are covered by packaging instructions PI968, PI969 and PI970.
Non-lithium batteries such as alkaline, nickel-metal hydride (NiMH) or nickel-cadmium (NiCd) fall under other UN numbers: UN2794 (wet batteries containing acid), UN2795 (wet batteries containing alkali), UN2800 (non-leaking wet batteries), and UN3028 (dry batteries containing potassium hydroxide). These have their own packaging instructions, such as PI870.
Different restrictions apply to each battery type in terms of capacity, number per package and state of charge (SoC). For example, loose lithium-ion batteries may only be carried on passenger aircraft with a maximum SoC of 30%.
The correct documentation is crucial for the safe and legal transport of batteries via air freight. Depending on the type of battery and method of dispatch, different documents are required.
For most battery shipments, a Shipper’s Declaration for Dangerous Goods (DGD) is required. This document must contain all details regarding the shipment, including:
For some battery shipments, such as lithium-ion batteries in equipment (PI967) and lithium-metal batteries in equipment (PI970) under Section II, a full DGD is not required. Instead, a Lithium Battery Mark and a Lithium Battery Document are sufficient. This document contains information on the type of lithium batteries, confirmation that the batteries meet the required tests, and instructions in the event of an incident.
In addition to these specific documents, general transport documents such as an Air Waybill are also required. The Air Waybill must state that the consignment contains dangerous goods, with a reference to the relevant DGD.
Ensure that all documentation is completed accurately and in full, as errors or missing information may lead to delays, fines or refusal of the shipment.
IATA sets specific packaging requirements for each battery type to ensure safe transport. These requirements vary depending on the type of battery, its capacity, and whether they are shipped loose or in equipment.
For lithium-ion batteries (UN3480) shipped loose, packaging instruction PI965 applies. These batteries must:
Different rules apply to lithium-ion batteries packed with equipment (UN3481, PI966) and lithium-ion batteries in equipment (UN3481, PI967). Batteries in equipment must be protected against accidental activation, and the device must be secured against accidental operation.
Lithium metal batteries have similar requirements but fall under PI968 (loose batteries), PI969 (packed with equipment) and PI970 (in equipment). Here, the amount of lithium metal per cell or battery is a key factor.
For non-lithium batteries such as alkaline, NiMH or wet batteries, different packaging instructions apply. Wet batteries, for example, must be leak-proof and placed in an acid-resistant inner packaging.
All battery packaging must withstand normal transport conditions and prevent the batteries from moving within the packaging. For certain battery types, UN-certified packaging is required that meets specific tests for drop resistance, stacking pressure and leak resistance.
Failure to comply with IATA regulations for battery transport can have serious consequences, both in terms of safety and legally and financially.
In terms of safety, incorrectly packaged or documented batteries can lead to incidents such as fire or explosion during transport. This endangers not only the air cargo, but also the aircraft, the crew and any passengers. Lithium batteries have been involved in several aviation incidents, which explains the strict regulations.
The legal consequences include fines that can run into tens of thousands of euros per offence. In some countries, repeated or serious offences may even lead to criminal prosecution. Aviation authorities such as EASA in Europe and the FAA in the US carry out regular inspections and can impose severe penalties.
In addition to fines, offenders may also face:
Airlines and cargo handlers have become increasingly strict in checking battery shipments. Many companies use advanced detection equipment to identify undeclared or incorrectly packaged batteries.
For companies that regularly ship batteries, it is therefore essential to invest in the right training, certification and packaging materials. The costs of this are significantly lower than the potential fines and other negative consequences of non-compliance.
If you regularly ship batteries for defence purposes or other applications, it is wise to work with a packaging partner specialising in the right packaging solutions for dangerous goods. At Faes, we have extensive experience with packaging solutions for defence and are familiar with the specific requirements for the safe transport of sensitive equipment, including batteries.
By taking the right measures and working with experts, you can ensure that your battery shipments reach their destination safely and in compliance with all regulations.
To check whether your batteries comply with IATA regulations, you must first identify the exact type of battery (lithium-ion, lithium-metal, etc.) and the specifications such as capacity (Wh) or lithium content. Compare this information with the current IATA Dangerous Goods Regulations (DGR). Have your batteries tested by a certified laboratory in accordance with the UN Manual of Tests and Criteria, Part III, subsection 38.3. A specialist freight forwarder or packaging partner such as Faes can also assist you with a compliance check for your specific batteries.
If you are unsure about the correct classification of your battery, always consult the manufacturer’s technical specifications or the Safety Data Sheet (SDS). If uncertainty persists, it is advisable to contact a certified dangerous goods safety adviser (DGSA) or a specialist transport company. When in doubt, always classify according to the strictest category to avoid risks. IATA also offers a classification tool on its website that can help determine the correct category.
Damaged or defective batteries may not, in principle, be transported by air freight, unless under very specific conditions and with special approval. Separate packaging instructions apply to these batteries, such as P908 or LP904 for road transport. If transport is necessary, contact your national aviation authority and a specialist carrier for advice. Often, transport by road or sea is the only permitted option for damaged batteries.
Staff involved in preparing battery shipments must have completed IATA DGR (Dangerous Goods Regulations) training, specifically categories 1 and 6. This training must be repeated every 24 months to maintain certification. Depending on the role, additional training may be required, such as for completing the Shipper’s Declaration. In the Netherlands, organisations such as EVO Fenedex, IATA Training and various logistics training institutes offer these certifications.
