Shipping Lithium Batteries: IATA Rules and Carrier Requirements

Lithium batteries are classified as dangerous goods under IATA (International Air Transport Association) Dangerous Goods Regulations (DGR). They present a fire and explosion risk, and aviation incidents involving lithium battery fires have driven progressively stricter shipping rules. Failure to comply can result in shipments being refused, returned, destroyed, and penalties imposed on shippers.

The Four UN Numbers Explained

All lithium batteries in international shipping fall under four UN numbers. The chemistry (lithium ion vs. lithium metal) and the configuration (standalone vs. with equipment) determine which applies.

| UN Number | Chemistry | Configuration | Typical Products | |-----------|-----------|---------------|-----------------| | UN 3480 | Lithium ion | Standalone (not in or with equipment) | Replacement phone batteries, laptop battery packs sold separately, spare power tool batteries | | UN 3481 | Lithium ion | Packed with or contained in equipment | Phones, laptops, tablets, power banks, power tools — any device shipped as a product | | UN 3090 | Lithium metal | Standalone | Button cells shipped separately, military batteries, certain medical device batteries | | UN 3091 | Lithium metal | Packed with or contained in equipment | Devices with non-rechargeable lithium metal cells (remote controls, watches, some cameras) |

Lithium ion is the chemistry in rechargeable consumer devices. Lithium metal is found in primary (non-rechargeable) cells — button cells, coin cells, and certain specialized batteries. Most commercial shippers deal primarily with lithium ion (3480/3481).

Section I vs. Section II: The Key Regulatory Division

IATA DGR divides lithium battery shipments into two sections with very different compliance requirements.

Watt-Hour Thresholds for Section Classification

| Battery Type | Section II Threshold (per cell) | Section II Threshold (per battery) | Section I Trigger | |-------------|--------------------------------|-------------------------------------|------------------| | Lithium ion cell | ≤ 20 Wh | — | > 20 Wh per cell | | Lithium ion battery | — | ≤ 100 Wh | > 100 Wh per battery | | Lithium metal cell | ≤ 1 g lithium content | — | > 1 g per cell | | Lithium metal battery | — | ≤ 2 g lithium content | > 2 g per battery |

Section II (Lower Restriction): Applies to smaller shipments meeting thresholds above. Simpler documentation, accessible to more carriers, can travel on passenger aircraft with quantity limits. Still requires lithium battery mark, state-of-charge compliance (for standalone), and proper packaging.

Section I (Full Dangerous Goods): Required for batteries above thresholds or quantities exceeding Section II limits. Requires:

Full Shipper's Declaration for Dangerous Goods (DGD)
UN-specification packaging with UN mark
Dangerous goods-trained shipper staff
Prior carrier approval
Class 9 dangerous goods label (yellow diamond)
Cargo aircraft only for large standalone batteries

Watt-Hour Calculation

The Wh rating is the key number for classification. If it is not printed on the battery:

Wh = Voltage (V) × Capacity (Ah)

Note: capacity is often printed in milliampere-hours (mAh). Convert: 1,000 mAh = 1 Ah.

Examples:

Smartphone battery: 3.85V × 3,500 mAh (3.5 Ah) = 13.5 Wh — well within Section II cell limit of 20 Wh
Laptop battery: 11.4V × 5,000 mAh (5 Ah) = 57 Wh — below 100 Wh battery limit, Section II
Power bank (large): 3.7V × 30,000 mAh (30 Ah) = 111 Wh — exceeds 100 Wh, Section I for standalone
E-bike battery: 48V × 12.5 Ah = 600 Wh — Section I, cargo aircraft only, prior carrier approval required

For battery packs made up of multiple cells, the total pack Wh is what matters for the battery-level threshold, while each individual cell's Wh matters for the cell-level threshold. Both must be within Section II limits to avoid Section I classification.

IATA Packing Instructions (PI 965–970)

IATA assigns specific Packing Instructions to each UN number and section:

| Packing Instruction | UN Number | Section | Summary | |--------------------|-----------|---------|---------| | PI 965 | UN 3480 | Section I | Standalone lithium ion batteries, full DG requirements | | PI 965 | UN 3480 | Section II | Standalone lithium ion batteries, simplified requirements | | PI 966 | UN 3481 | Section I | Lithium ion batteries packed with equipment, full DG | | PI 966 | UN 3481 | Section II | Lithium ion batteries packed with equipment, simplified | | PI 967 | UN 3481 (contained) | Section I/II | Lithium ion batteries contained in equipment | | PI 968 | UN 3090 | Section I | Standalone lithium metal batteries, full DG | | PI 968 | UN 3090 | Section II | Standalone lithium metal batteries, simplified | | PI 969 | UN 3091 | Section I/II | Lithium metal packed with equipment | | PI 970 | UN 3091 (contained) | Section I/II | Lithium metal contained in equipment |

Each packing instruction specifies: maximum quantities per package, packaging requirements, marking and labeling requirements, and whether the shipment may travel on passenger aircraft.

The current IATA DGR edition (updated annually) is the authoritative source. The edition in force on your shipping date applies.

State-of-Charge Requirements

Standalone lithium ion batteries (UN 3480) shipped by air must have a state of charge (SoC) not exceeding 30% of their rated capacity. This is a critically important requirement that many shippers miss.

At 30% SoC, a lithium ion battery has reduced thermal runaway risk because there is less stored energy available to fuel a fire. The 30% requirement does not apply to batteries contained in or packed with equipment (UN 3481) for Section II shipments, though some carriers apply it anyway.

How to verify SoC:

Discharge the battery to approximately 30% before packing
Use battery management system readouts where available
For power banks: charge the device to 30% (usually indicated by 1 light on a 3-light indicator)

Documentation of SoC compliance may be required by some carriers. Retain a record of how compliance was achieved.

Carrier Comparison: Battery Acceptance Policies

IATA DGR sets the minimum standard. Individual carriers apply stricter rules, and policies change. The following is a general guide — verify directly with each carrier before booking.

| Carrier | UN 3480 (Standalone) | UN 3481 (With Equipment) | Key Restrictions | |---------|---------------------|--------------------------|-----------------| | DHL Express | Section II accepted; Section I requires Dangerous Goods Account | Widely accepted for consumer goods | Some country pairs restricted; DHL has its own battery acceptance criteria | | FedEx | Section II accepted with proper documentation; Section I requires DG specialist service | Accepted; FedEx has specific e-commerce battery programs | FedEx publishes a Dangerous Goods Shipping Guide updated periodically | | UPS | Section II accepted; Section I requires UPS Dangerous Goods service | Accepted; proper documentation required | UPS has country-level restrictions; some origin-destination pairs blocked for certain battery types | | USPS | Section II in limited quantities for domestic; international restrictions are significant | Domestic consumer goods accepted; international very limited | USPS prohibits most standalone battery shipments internationally; domestic only for higher quantities | | Postal operators (general) | Highly restricted; most postal networks do not accept standalone lithium ion batteries above small Section II quantities | Consumer goods with batteries generally accepted in domestic postal; international postal highly variable | Do not assume postal rules match express courier rules |

Always confirm current carrier rules before booking. Policies change when incidents occur, regulations are updated, or carrier risk assessments change. A shipment accepted last year may be refused today under revised carrier guidelines.

Shipping Power Banks Specifically

Power banks are UN 3481 (lithium ion batteries contained in equipment — the equipment being the power bank housing with USB ports). Classification:

≤ 100 Wh: Section II, UN 3481, PI 967. Accepted on passenger aircraft with quantity limits. Most consumer power banks (up to approximately 27,000 mAh at 3.7V) fall here.
100–160 Wh: Section I, cargo aircraft only, prior carrier approval required. High-capacity power banks fall here.
> 160 Wh: Prohibited on passenger aircraft; Section I, cargo aircraft only with carrier approval and full DG documentation.

Power banks with defective cells, bulging casings, or damage must not be shipped at all. Damaged lithium batteries are subject to separate, even stricter rules.

E-Bike Battery Shipping

E-bike batteries are typically 36V–52V, 10–20 Ah, equating to 360–1040 Wh. This means:

All e-bike batteries fall under Section I
Cargo aircraft only — passenger aircraft transport is prohibited
Full Shipper's Declaration for Dangerous Goods required
UN-specification packaging required
Prior carrier approval required — not all carriers accept e-bike batteries

Most major express carriers (DHL, FedEx, UPS) will accept e-bike batteries as Section I dangerous goods shipments when properly declared and packaged, typically via their specialized dangerous goods services with advance booking. Surface (road/rail/sea) freight faces different regulations and generally imposes lower restrictions on e-bike battery shipments, making surface freight the practical standard for e-bike battery commerce.

Recalled and Damaged Batteries

Lithium batteries subject to a safety recall or that are damaged, defective, or identified as posing a safety risk are subject to special provisions under IATA DGR that apply additional restrictions beyond standard Section I requirements.

Do not ship recalled batteries by air. Many recalled batteries are prohibited from all air transport, including cargo aircraft. Surface transport under special permits may be possible for disposal and recycling.

Damaged batteries (punctured, swollen, leaking, or previously involved in a thermal event) must be handled by specialized dangerous goods handlers. Do not attempt to ship them through standard courier or freight services.

Labeling and Marking Requirements

Lithium Battery Mark (All Section II Shipments)

The lithium battery mark is a rectangular label (minimum 120mm wide × 110mm tall) with:

A lithium battery symbol (battery graphic with flame)
The UN number (3480, 3481, 3090, or 3091)
A telephone number for emergency information (must be reachable 24 hours; the shipper's contact or a DG emergency response service)

Class 9 Label (Section I Shipments)

A white and black striped diamond label (Class 9 Miscellaneous Dangerous Goods). Required on all Section I packages. Dimensions: minimum 100mm × 100mm.

Additional Markings for Section I

UN number in format "UN XXXX" on the outer package
Proper shipping name: "LITHIUM ION BATTERIES" (UN 3480) or "LITHIUM ION BATTERIES PACKED WITH EQUIPMENT" (UN 3481)
Shipper name and address
Consignee name and address
Gross weight if over 30 kg
"CARGO AIRCRAFT ONLY" label where required (standalone batteries above certain quantities, Section I)

Orientation Labels

Required when inner packaging can leak: "This Way Up" arrows on two opposite sides of the package.

Shipper's Declaration for Dangerous Goods

For Section I shipments, the Shipper's Declaration for Dangerous Goods (DGD) is a mandatory document completed by the shipper and handed to the carrier. Key fields:

Shipper and consignee names and addresses
Air waybill number (or indication "Not Restricted" for Section II)
UN number, proper shipping name, hazard class (9), packing group (where applicable)
Quantity and type of packaging
Packing instructions followed
Authorization statement and shipper's signature

The DGD must be completed by trained dangerous goods personnel. Errors on the DGD can result in shipment refusal or regulatory penalties. Many carriers provide their own DGD templates; IATA also provides a standard form.

Practical Steps for Shippers

Identify the Wh rating of every battery in the shipment — check the battery label, device documentation, or calculate from voltage and capacity
Determine the UN number — standalone (3480/3090) or with equipment (3481/3091)?
Determine Section based on Wh thresholds and quantity
Check state-of-charge — discharge standalone batteries to ≤30% before packing
Confirm current carrier rules before booking — call or check carrier DG portal
Prepare packaging — short circuit protection, movement prevention, robust outer packaging, UN-spec for Section I
Apply correct marks and labels — lithium battery mark for Section II, Class 9 + UN number for Section I
Prepare documentation — commercial invoice, packing list, DGD for Section I, air waybill
For Section I: Use a certified dangerous goods shipper or ensure staff have completed IATA DGR training (Category 6 for shippers)

Do not attempt to misrepresent battery capacity to avoid classification. Carriers conduct random checks of declared specifications, and customs authorities may require physical testing. Misrepresentation constitutes dangerous goods fraud, with severe penalties including criminal prosecution in many jurisdictions.