Shipping Lithium Batteries by Air: UN3480 and UN3481 Rules

Lithium batteries fly only as declared dangerous goods under the IATA Dangerous Goods Regulations, using the right UN number (UN3480, UN3481, UN3090 or UN3091), packing instruction, marks and documents. Standalone batteries (UN3480 and UN3090) are forbidden as cargo on passenger aircraft, while UN3481 and UN3091 batteries packed with or contained in equipment can fly on passenger aircraft up to 5 kg of batteries per package. UN3480 must ship at no more than 30% state of charge, and since 1 January 2026 the 30% limit also applies to lithium-ion batteries packed with equipment.

Can UN3481 or UN3090 fly on passenger aircraft?

UN3481 can: lithium-ion batteries packed with or contained in equipment may fly on passenger aircraft up to 5 kg net weight of batteries per package. UN3090 cannot: lithium metal batteries shipped on their own are forbidden as cargo on passenger aircraft and must fly on freighters with a Cargo Aircraft Only label.

Those are the limits in the IATA Lithium Battery Guidance Document revised for the 2026 regulations (67th edition DGR). The same split applies to all four UN numbers:

PI 968 has no Section II in the current regulations: every UN3090 package is prepared under Section IA or IB and must carry the Cargo Aircraft Only label. For batteries in equipment, the limit is the net weight of the batteries, not the equipment or packaging. Under Special Provision A201, lithium metal batteries within set quantity limits may fly on a passenger aircraft only with approval from the States of Origin, Destination and the Operator, or, for urgent medical need, as a single consignment with approval from the State of Origin and the operator. UN3480 likewise needs A201 approval to go on a passenger aircraft. Individual airlines may also restrict UN3481 and UN3091 further through operator variations, so confirm acceptance for your flight.

Standalone lithium batteries (UN3480 and UN3090) can only fly on freighters, while batteries packed with or contained in equipment can fly on passenger aircraft within the per-package limits; damaged, defective or recalled batteries are generally forbidden on both.

Batteries that have not passed UN 38.3 may move only under State approval (Special Provision A88). Waste batteries and batteries shipped for recycling are forbidden by air unless approved under A183, which matters for e-commerce returns and electronics recycling. Because standalone batteries are freighter-only, capacity on your lane depends on main-deck or lower-deck freighter service, not just the overall flight schedule.

Why are lithium batteries regulated in air transport?

Because a damaged, defective or short-circuited lithium cell can overheat and ignite in a chain reaction known as thermal runaway, which is hard to extinguish in a cargo hold.

For that reason lithium batteries are classified as Class 9 dangerous goods. The rules are set by ICAO's Technical Instructions for the Safe Transport of Dangerous Goods by Air and published for industry use in the IATA Dangerous Goods Regulations (DGR), updated every year with a new edition effective 1 January. The current IATA Lithium Battery Guidance Document is based on the 2025-2026 ICAO Technical Instructions and the 67th edition (2026) of the DGR. In the United States, the Hazardous Materials Regulations also apply, with lithium batteries covered in 49 CFR 173.185, and the FAA enforces them for air shipments.

Lithium batteries are one class within a wider system. For the basics that apply to every dangerous goods shipment, see our guide to dangerous goods air freight and the nine hazard classes.

Which UN number applies to my batteries: UN3480, UN3481, UN3090 or UN3091?

It depends on the chemistry (lithium-ion or lithium metal) and whether the batteries ship alone, packed with equipment or installed in it.

Lithium-ion batteries are rechargeable and include lithium polymer and lithium iron phosphate types; they power phones, laptops, power tools and e-bikes. Lithium metal batteries are generally non-rechargeable and power watches, cameras, key fobs and many temperature data loggers. IATA's guidance is explicit that power banks are classified as batteries, not as batteries contained in equipment, so a carton of power banks ships as UN3480.

The DGR also now covers sodium-ion batteries under UN3551 and UN3552, with their own packing instructions (PI 976 to 978). They follow a similar structure but are outside the scope of this guide.

How do packing instructions 965 to 970 and their sections work?

Each packing instruction is split into sections by battery size: Section I (and IA/IB for standalone batteries) for fully regulated shipments, and Section II for smaller batteries with lighter requirements.

For lithium-ion, the size thresholds are 20 Wh per cell and 100 Wh per battery. For lithium metal, they are 1 g of lithium per cell and 2 g per battery. The IATA guidance document sets out the per-package limits for each route:

The limits for PI 969 and PI 970 (lithium metal with or in equipment) follow the same pattern as PI 966 and PI 967. Limits for equipment are generally net battery mass, not gross package weight. Always confirm against the current DGR entry, because these figures change between editions.

Section II is not the same as "unregulated." It still requires strong outer packaging, protection against short circuits, the lithium battery mark in most cases and a compliance statement on the air waybill. Staff preparing Section II shipments do not need full DGR training, but IATA requires them to receive documented "adequate instruction."

What is the 30% state-of-charge rule, and does it now apply to UN3481?

Lithium-ion batteries shipped on their own (UN3480, PI 965) must be at no more than 30% of rated capacity, and from 1 January 2026 the same limit applies to lithium-ion batteries packed with equipment (UN3481, PI 966).

According to the IATA Lithium Battery Guidance Document for 2026, the change was adopted by ICAO into the 2025-2026 Technical Instructions because a lower charge reduces the chance of a cell going into thermal runaway. Here is how it applies by configuration:

Shipping above these limits is possible only with written approval from the State of Origin and the State of the Operator under Special Provision A331. In practice, that means the battery or equipment manufacturer needs a process to discharge or ship at reduced charge, and the shipper needs evidence of it. Some airlines apply stricter rules than the DGR minimum through operator variations, so check before booking.

Which labels, marks and documents does a lithium battery shipment need?

Section I packages carry the Class 9 lithium battery hazard label and a Shipper's Declaration, standalone batteries also need the Cargo Aircraft Only label, Section II and IB packages carry the lithium battery mark, and every battery type needs a UN 38.3 test summary.

Labels and marks

• Class 9 lithium battery hazard label: the Class 9 diamond with seven vertical black stripes in the top half and a battery symbol in the bottom half. Required on Section I and Section IB packages, along with the UN number and proper shipping name.
• Cargo Aircraft Only (CAO) label: required on all packages prepared under PI 965 (UN3480) and PI 968 (UN3090), Sections IA and IB, and wherever else the DGR limits a shipment to freighters.
• Lithium battery mark: a rectangle with red hatched borders showing the UN number and a contact telephone number, at least 100 mm x 100 mm (or 100 mm x 70 mm on small packages). Required for Section II of PI 966, 967, 969 and 970, and for Section IB in addition to the hazard and CAO labels.

Small Section II consignments of equipment can be exempt from the battery mark, for example packages containing only button cells installed in equipment, or consignments of no more than two packages where each holds no more than four cells or two batteries installed in equipment.

Documents, including the UN 38.3 test summary

• UN 38.3 test summary: manufacturers and later distributors of cells, batteries and battery-powered equipment must make it available. It names the manufacturer and test laboratory, gives a unique test report number and date, describes the battery (chemistry, mass, watt-hour rating or lithium content, model numbers), lists the tests and results, and is signed off by a responsible person. A website link or QR code on the packaging or documents is acceptable instead of paper copies.
• Shipper's Declaration for Dangerous Goods: required for Section I and Section IB shipments, completed and signed by a person trained under DGR subsection 1.5.
• Air waybill statements: Section II shipments carry a compliance statement, such as "Lithium ion batteries in compliance with Section II of PI 966," in the nature and quantity of goods box.
• State approvals where a special provision requires them, such as A88 for prototypes and low production runs, A99 for batteries over 35 kg, A183 for waste and recycling, and A331 for lithium-ion above 30% charge.

IATA notes that UN3480 and UN3090 packages must not share an outer packaging or overpack with explosives (other than 1.4S), flammable gases, flammable liquids, flammable solids or oxidizers.

How do you ship lithium batteries by air without delays?

1. Identify the chemistry, watt-hour rating or lithium content and configuration of every SKU, and map each to its UN number, packing instruction and section.
2. Collect UN 38.3 test summaries before the first shipment.
3. Confirm state of charge: 30% or less for UN3480 and, from 2026, for lithium-ion packed with equipment.
4. Check the airline accepts the UN number on your route and aircraft type, including operator variations.
5. Use packaging that prevents short circuits, damage and accidental activation, and apply the right labels and marks.
6. Declare correctly every time. Undeclared batteries are a safety risk and can lead to FAA civil penalties.

If you ship batteries occasionally, a forwarder with DG-trained staff and battery experience is the safest route. Our checklist for choosing a dangerous goods forwarder or 3PL covers what to ask. For smartphones, laptops and other valuable electronics, JumboSecure combines monitored, high-security transport with handling arranged around DG requirements, and you can check costs early with the chargeable weight calculator.

Frequently asked questions

Can UN3481 fly on passenger aircraft?

Yes. Lithium-ion batteries packed with equipment (PI 966) or contained in equipment (PI 967) may fly on passenger aircraft up to 5 kg net weight of batteries per package, under both Section I and Section II, according to IATA's 2026 Lithium Battery Guidance Document. Airline operator variations can be stricter.

Can UN3090 be shipped on passenger flights?

No. Lithium metal batteries shipped by themselves (UN3090, PI 968 Sections IA and IB) are forbidden as cargo on passenger aircraft and need a Cargo Aircraft Only label. The only exceptions are State approvals under Special Provision A201, including one consignment for urgent medical need with State of Origin and operator approval.

What is the difference between UN3480 and UN3481?

UN3480 is lithium-ion batteries shipped on their own. UN3481 is lithium-ion batteries packed with equipment (in the same box but not installed) or contained in equipment (installed in the device).

Can I ship UN3480 on a passenger flight?

No. Lithium-ion batteries shipped by themselves are forbidden as cargo on passenger aircraft unless the relevant authorities approve it under Special Provision A201, so they move on freighters with a Cargo Aircraft Only label.

Does the 30% state-of-charge rule apply to UN3481?

Since 1 January 2026 it applies to lithium-ion batteries packed with equipment (PI 966): all Section I batteries, and Section II batteries above 2.7 Wh. For batteries contained in equipment (PI 967), IATA strongly recommends 30% (or 25% indicated capacity) but does not require it.

What is a UN 38.3 test summary?

A document confirming the cell or battery type passed the tests in sub-section 38.3 of the UN Manual of Tests and Criteria. Manufacturers and later distributors must make it available, for example through a website link or QR code.

How do I find a battery's watt-hour rating?

It is usually marked on the battery. If not, multiply the nominal voltage by the capacity in ampere-hours; for example, 3.7 V x 4.4 Ah = 16.3 Wh.

Sources

1. IATA: Lithium Battery Guidance Document, revised for the 2026 regulations
2. IATA: Lithium batteries
3. IATA: Dangerous Goods Regulations (DGR)
4. U.S. FAA: Lithium Battery Resources
5. U.S. eCFR: 49 CFR 173.185, Lithium cells and batteries

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