Introduction

Shipping lithium cells and batteries by air is more restrictive than ground, as a result, it isn’t always the first choice for transportation. However, sometimes the situation doesn’t allow for transportation by ground, which leaves you no choice but to ship by air. When shipping lithium cells and batteries by air, shippers must adhere to the requirements of 49 CFR and the International Air Transport Association (IATA) Dangerous Goods Regulations (DGR).

Both regulations must be followed because the 49 CFR regulates hazardous materials transportation in the United States, and IATA requires its members to use the IATA DGR. IATA members consist of most of the world’s airlines that account for 82% of total air traffic. IATA members include:

• American Airlines
• United Airlines
• FedEx Express
• UPS Airlines
• Lufthansa
• Virgin Atlantic
• DHL Air

IATA also produces an annual lithium battery guidance document that should be referenced when shipping lithium cells or batteries by air. The guidance document provides information on:

• Definitions
• Classifications
• Prohibitions
• Restrictions
• FAQ’s

General Requirements

As the shipper it is your responsibility to ensure that all the requirements for shipping lithium batteries are met. If, for any reason, not all requirements are met, you should not offer the batteries for shipment.

Lithium cell and battery restrictions include:

• Cells or batteries must meet the requirements of the UN Manual of Tests and Criteria
• Cells or batteries that are damaged, defective, or known to be unsafe cannot be shipped
• Test summary must be made accessible
• Lithium ion cells or batteries (UN3480) must not be shipped with more than 30% state of charge
• Lithium ion and metal cells or batteries (UN3480 and UN3090) are forbidden for shipment as cargo on passenger aircraft.

Lithium cells and batteries must be properly classified. The following seven classifications can be used for transportation by air:

1. UN3480 Lithium ion batteries
2. UN3481 Lithium ion batteries packed with equipment
3. UN3481 Lithium ion batteries contained in equipment
4. UN3090 Lithium metal batteries
5. UN3091 Lithium metal batteries packed with equipment
6. UN3091 Lithium metal batteries contained in equipment
7. UN3171 Battery-powered vehicle

UN3171 Battery-powered vehicle can only be used with vehicles that are solely powered by the lithium battery and do not have an internal combustion engine, such as a fully battery powered car.

Packaging

All applicable Packing Instructions 965 through 970 found in section 5 of the IATA DGR must be met when shipping by air.

Lithium cells or batteries, including those packed with or contained in equipment, must also be packaged in a way that prevents:

• Short circuits
• Movement within the outer package
• Accidental activation of equipment
• Release of contents

Lithium cells or batteries, including those packed with equipment, must be completely enclosed in a non-metallic inner packaging that separates the cells or batteries from contact with equipment, devices, or conductive materials such as metal. The UN rated package must meet Packing Group II requirements.

Marking and Labeling

The marking requirements for fully regulated lithium cells or batteries are the same as other hazardous materials. The package should still be marked with the:

• ID number
• Propper shipping name
• Shipper’s or receiver’s name and address, when required
• Special permit number, when required

The labeling requirements for fully regulated lithium cells or batteries will change slightly compared to other hazardous materials. A Class 9 label would still be required on the package. However, you would need to use the Class 9 lithium battery label that has the battery image on it instead of using the normal Class 9 label.

Packages containing lithium cells or batteries that are not allowed or forbidden for transport on passenger aircraft must have the “Cargo Aircraft Only” label applied.

Shipping Papers

Fully regulated lithium cells or batteries are required to have shipping papers. IATA requires shippers to use the Shipper’s Declaration for Dangerous Goods form when shipping hazardous materials.