Lithium batteries remain one of the most regulated categories in air freight. With the 2026 edition of the IATA Dangerous Goods Regulations (DGR) now in effect, shippers need to stay current on the latest requirements for shipping lithium-ion (Li-ion) and lithium-metal batteries by air.
Key Changes in the 2026 IATA DGR
The 2026 regulations introduce several important updates. State of Charge (SoC) limits for lithium-ion cells shipped as cargo on passenger aircraft remain at 30% maximum. New labeling requirements specify minimum label dimensions of 120×110 mm for cargo packages, with updated hazard class marks. Enhanced documentation requirements now mandate that shippers include battery test summary information on the Dangerous Goods Declaration (DGD). Packaging standards have been tightened — inner packaging must now prevent movement of cells within the outer package under normal transport conditions.
Classification: Which UN Numbers Apply?
Lithium batteries fall under four UN numbers depending on type and packing configuration. UN3480 covers lithium-ion batteries shipped alone (standalone). UN3481 applies to lithium-ion batteries packed with or contained in equipment (laptops, phones, power tools). UN3090 covers lithium-metal batteries alone. UN3091 is for lithium-metal batteries packed with or contained in equipment. Each UN number has different packing instructions (PI965–PI970) with specific quantity limits and packaging requirements.
Packing Instructions at a Glance
Section II of each packing instruction allows shipment without a full DGD if the batteries meet size and quantity limits. For UN3481 Section II (Li-ion in equipment): maximum 5 kg net weight of batteries per package, each cell ≤20 Wh, each battery ≤100 Wh. Exceeding these limits requires Section I compliance with full DGD, certified packaging, and dangerous goods acceptance by the airline. Section IB (new in recent editions) has intermediate limits and requirements.
Common Mistakes That Cause Rejection
Airlines reject lithium battery shipments more than any other dangerous goods category. The most common errors include: missing or incorrect lithium battery handling label, SoC exceeding 30% for standalone batteries on passenger aircraft, incorrect UN number classification, packages that fail the 1.2-metre drop test requirement, missing battery test summary reference, and using non-UN-certified packaging for Section I shipments. Each rejection costs time and money — typically 2–5 day delays plus rebooking fees.
Carrier-Specific Restrictions
Individual airlines may impose restrictions beyond IATA minimums. Some airlines do not accept standalone lithium batteries (UN3480/UN3090) at all, even on freighter aircraft. Others limit maximum battery capacity per package or per shipment. Always verify your chosen airline’s specific acceptance policy before booking. Major carriers with published lithium battery policies include Lufthansa Cargo, Emirates SkyCargo, Cathay Pacific Cargo, and Singapore Airlines Cargo.
Frequently Asked Questions
Can I ship lithium batteries on passenger aircraft?
What training is required to ship lithium batteries by air?
What happens if my lithium battery shipment is rejected?
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