IATA DGR - Battery Design

IATA Dangerous Goods Regulations — Lithium Battery Air Transport

The IATA Dangerous Goods Regulations (DGR) is the standard reference for the safe transport of dangerous goods by air, published annually by the International Air Transport Association (IATA). Section 3.9 and Section 9.3 of the DGR contain the specific requirements for lithium batteries transported as air cargo or in passenger baggage. The DGR supplements the ICAO Technical Instructions and is the primary working document used by airlines, freight forwarders, and shippers for air transport compliance.

Published by: International Air Transport Association (IATA)
Current edition: IATA DGR (65th edition, 2024 — updated annually)
Legal basis: ICAO Technical Instructions for the Safe Transport of Dangerous Goods by Air
Related standard: UN 38.3 (battery transport testing, prerequisite for air shipment)
US domestic equivalent: PHMSA / 49 CFR HMR (governs the same batteries once they move by US road/rail rather than air)

Scope

The IATA DGR applies to all lithium batteries (lithium metal and lithium-ion) transported by air, whether as standalone batteries, batteries in equipment, or batteries with equipment. It specifies packaging, labelling, documentation, quantity limits, and carriage conditions for batteries as dangerous goods UN 3090, 3091, 3480, and 3481.

Key Requirements for Lithium Batteries

State-of-Charge and Packaging

Lithium-ion cells and batteries transported as cargo must be at a state of charge not exceeding 30% (for PI 965 and PI 968 cargo batteries). Batteries must be individually protected to prevent short circuits and packed in strong outer packaging. Each package must not exceed defined maximum gross weights and quantity limits.

Labels, Marks, and Documentation

Packages must bear the lithium battery handling label (IATA lithium battery label or UN 3480/3481 marks depending on classification). Shipments must be accompanied by a Shipper’s Declaration for Dangerous Goods (for Section II quantities, a declaration may not be required, but the lithium battery handling label and mark are still mandatory). UN 38.3 test compliance must be documentable on demand.

Disclaimer: This is not a definitive guide, just an indication and it is important that you always go back to the source for legislation.