Can Lithium Batteries Be Transported by Air?
Lithium batteries can be transported by air, but the exact requirements vary depending on the battery type and how it is presented for shipment.
Lithium-ion batteries are rechargeable and are commonly found in phones, laptops and power tools. Lithium-metal batteries are generally non-rechargeable and are often used in watches, sensors and specialist equipment.
The regulations also distinguish between batteries that are:
- Shipped separately
- Packed alongside equipment
- Installed inside equipment
Standalone lithium-ion and lithium-metal batteries are not permitted as cargo on passenger aircraft. They may still travel on approved cargo aircraft when the relevant conditions are met. Batteries packed with or contained in equipment may be accepted on passenger aircraft, depending on their size, quantity, state of charge and packaging.
Why Are Lithium Batteries Classed as Dangerous Goods?
Lithium batteries contain a large amount of energy within a relatively small space. If a battery is damaged, overheats or short-circuits, it can enter a process known as thermal runaway.
Thermal runaway causes the battery temperature to rise rapidly and can result in fire, smoke or explosion. A lithium battery fire inside an aircraft cargo hold is particularly difficult to manage, making prevention essential.
The UK Civil Aviation Authority has identified incorrectly packed, labelled or declared batteries as a recurring concern. Undeclared batteries can be especially dangerous because handling teams and aircraft operators may not know that additional safety precautions are required.
Air Freight Regulations for Lithium Batteries
The international requirements for transporting dangerous goods by air are set out in the International Civil Aviation Organization Technical Instructions. Airlines and freight operators also use the IATA Dangerous Goods Regulations when accepting and handling shipments.
Lithium batteries are classified as Class 9 miscellaneous dangerous goods. The main classifications are:
- UN 3480: Lithium-ion batteries shipped separately
- UN 3481: Lithium-ion batteries packed with or contained in equipment
- UN 3090: Lithium-metal batteries shipped separately
- UN 3091: Lithium-metal batteries packed with or contained in equipment
The correct classification affects the packaging, labels, documentation and aircraft options available.
Most battery types must also have passed the applicable UN 38.3 tests. Manufacturers and subsequent distributors are required to make a test summary available, although it does not normally need to travel as a paper document with every shipment.
State-of-charge restrictions can also apply. Standalone lithium-ion batteries must generally be shipped at no more than 30% of their rated capacity, and similar limits now apply to many lithium-ion batteries packed with equipment.
As requirements are regularly updated, businesses should check the current rules for every consignment rather than relying on the instructions used for an earlier shipment.
Packaging and Labelling Requirements
Correct packaging helps protect batteries from movement, impact, short circuits and accidental activation.
Battery terminals should be covered or separated so they cannot touch other batteries, metal objects or conductive materials. Batteries must be secured inside suitable packaging and should not be able to move during handling or transit.
A strong, rigid outer package is generally required unless a battery installed inside equipment receives equivalent protection from the equipment itself. Devices should also be packed so that they cannot switch on accidentally during the journey.
The required marks and labels depend on the battery classification and packing instruction. These may include:
- The relevant UN number
- A lithium battery mark
- A Class 9 hazard label
- A Cargo Aircraft Only label
- Shipper and consignee information
A Shipper’s Declaration for Dangerous Goods may also be required. Small consignments of batteries contained in equipment can qualify for certain exceptions, so not every package will need the same labels or documents.
Batteries that are damaged, swollen, leaking or subject to a safety recall must not be placed into a normal air freight shipment. Batteries capable of producing dangerous heat, fire or a short circuit are forbidden from air transport.
Common Challenges When Shipping Lithium Batteries
One of the most common problems is incomplete product information. A business may know the product name but not the battery chemistry, watt-hour rating, net battery weight or UN classification.
Lithium batteries can also be easily overlooked when they are installed inside equipment. Products may be described simply as electronics, machinery or spare parts, even though they contain regulated batteries.
Other common challenges include unsuitable packaging, missing UN 38.3 test summaries and incorrect labels. Airline restrictions can create further complications, as individual operators may apply requirements that are stricter than the general regulations.
Returns can be particularly difficult. Before a used device is shipped, the condition of its battery must be established. A product being returned because of a broken screen is different from one being returned because its battery is overheating.
How JJX Logistics Can Help
Transporting lithium batteries by air involves more than securing space on an aircraft. The shipment must be assessed, correctly prepared and accepted by an airline that is able to carry it.
JJX Logistics provides air freight services for time-sensitive and regulated cargo, including dangerous goods. Our team can help businesses understand the information required, plan suitable routing and coordinate the movement from collection through to delivery.
By identifying potential issues early, JJX helps customers reduce the risk of rejected cargo, unexpected costs and delays. The result is an air freight service that is safe, compliant and dependable.
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