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Shipping lithium batteries by air: classification, packing and compliance

Lithium batteries are the most frequently mis-declared dangerous goods in air transport and the ones regulators and airlines watch most closely. The rules changed again on 1 January 2026, and they will change again in 2027. David led IATA's work on lithium battery transport for most of two decades and now helps shippers, manufacturers, e-commerce sellers and airlines get it right.

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Close-up of rows of battery cells

Where it usually goes wrong

  • Working out whether a product is UN 3480, 3481, 3090 or 3091, and whether it qualifies for Section II
  • State of charge limits, including the 30 per cent requirement that now applies to lithium ion cells and batteries packed with equipment
  • Packaging, marking and labelling that acceptance staff will pass
  • Power banks, e-bikes, drones, medical devices and returns of damaged or recalled batteries
  • Operator variations and airline embargoes that differ route by route

What the work includes

Each engagement is scoped to what you need; these are the components David draws on.

Classification and shipping assessment
A written determination for each product covering UN number, packing instruction, section, quantity limits and aircraft type, with the regulatory references.
Procedures, documents and training material
Shipper procedures, packing checklists, declaration templates and awareness material for staff who handle lithium battery consignments.
Approvals, exemptions and difficult shipments
Damaged, defective or recalled batteries, prototypes, large-format and vehicle batteries, and shipments that need a CASA or operator approval.

What you end up with

Battery shipments that move on the first attempt, and a compliance position that keeps pace with each edition of the regulations.

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