The transportation of lithium batteries by air is governed by stringent regulations to mitigate risks such as thermal runaway, fire, and explosion. The International Air Transport Association (IATA) Dangerous Goods Regulations (DGR) provide the framework for the safe transport of these batteries, with specific provisions for lithium-ion and lithium-metal batteries. Compliance with these rules is mandatory for shippers, freight forwarders, and airlines to ensure safety in air transport.

Lithium batteries are classified under two main categories in the IATA DGR: lithium-ion batteries (UN 3480) and lithium-metal batteries (UN 3090). Each category has distinct packaging instructions (PI) based on whether the batteries are shipped alone or contained in equipment. For lithium-ion batteries, PI 965 applies to batteries shipped alone, while PI 966 and PI 967 cover batteries packed with equipment or installed in equipment, respectively. Similarly, lithium-metal batteries fall under PI 968 for standalone shipments, PI 969 for batteries packed with equipment, and PI 970 for batteries installed in equipment.

A critical aspect of these regulations is the distinction between Section IA, Section IB, and Section II batteries. Section IA and IB apply to lithium-metal batteries, with Section IA covering those with more than 1 gram of lithium per cell or 2 grams per battery, and Section IB for those below these thresholds. Section II applies to lithium-ion batteries with a watt-hour rating not exceeding 20 Wh per cell or 100 Wh per battery. Batteries exceeding these limits are classified as fully regulated dangerous goods and require additional safeguards.

Packaging requirements under IATA DGR are designed to prevent short circuits, damage, and accidental activation. Batteries must be packed in strong outer packaging that meets specific drop and crush test standards. Inner packaging must separate individual batteries to avoid contact, and non-conductive material must be used to prevent short circuits. For lithium-ion batteries, the state of charge (SOC) must not exceed 30% for standalone shipments unless approved by the appropriate authority. Lithium-metal batteries must be shipped at a minimal charge.

Quantity limits vary depending on whether batteries are transported on passenger or cargo aircraft. For passenger aircraft, lithium-ion batteries under Section II are limited to a net quantity of 5 kg per package, while lithium-metal batteries under Section II are restricted to 2.5 kg per package. Cargo aircraft allow higher limits, with lithium-ion batteries permitted up to 35 kg per package and lithium-metal batteries up to 10 kg per package. Fully regulated shipments (Section IA and IB) have stricter limits and require hazardous materials declarations, proper labeling, and Class 9 hazard markings.

Recent updates to the IATA DGR reflect evolving safety concerns. As of 2023, the regulations prohibit the transport of standalone lithium-ion batteries as cargo on passenger aircraft unless they meet specific exceptions. This change was driven by incidents involving thermal runaway in cargo holds. Additionally, all lithium battery shipments must now include a shipper’s declaration for dangerous goods, even for Section II batteries, which were previously exempt. The updated rules also mandate enhanced crew training to handle potential in-flight battery fires.

Incident reporting is a crucial component of the regulatory framework. Airlines and shippers must report any incidents involving lithium batteries, including overheating, leakage, or fire, to the relevant national authority and IATA. Data from these reports inform future regulatory adjustments. For example, multiple incidents involving counterfeit or poorly manufactured batteries led to stricter requirements for traceability and testing documentation.

Airlines may impose additional restrictions beyond IATA DGR. Some carriers completely prohibit the transport of certain lithium battery types, while others enforce lower quantity limits or require pre-approval for shipments. These policies are often based on risk assessments and past incidents. Passengers are also subject to restrictions when carrying lithium batteries in personal devices or as spares. Spare batteries must be carried in carry-on baggage, with limits on energy ratings: lithium-ion batteries must not exceed 100 Wh, and lithium-metal batteries must not exceed 2 grams of lithium content.

The IATA DGR also addresses the transport of damaged, defective, or recalled batteries. Such shipments are classified as fully regulated dangerous goods and require special approval. Packaging must include additional containment measures to prevent leakage or thermal events. Recalled batteries often fall under this category due to their increased risk of failure.

Training and certification are mandatory for personnel involved in shipping lithium batteries by air. IATA offers dangerous goods training programs that cover classification, packaging, marking, labeling, and documentation. Recurrent training is required every two years to stay updated on regulatory changes. Non-compliance can result in fines, shipment rejections, or legal action.

The future of lithium battery air transport regulations will likely see further refinements as battery technology evolves. Emerging trends such as higher energy-density batteries and solid-state electrolytes may necessitate updates to testing standards and packaging requirements. Ongoing collaboration between industry stakeholders and regulatory bodies ensures that safety remains a priority while facilitating the global movement of these essential power sources.

In summary, the IATA DGR provides a comprehensive framework for the safe air transport of lithium batteries, with detailed classifications, packaging instructions, and quantity limits. Recent updates reflect lessons learned from incidents, and airline-specific policies add an extra layer of safety. Compliance with these regulations is essential to minimize risks and ensure the uninterrupted flow of battery-powered technologies across the globe.