The 67th edition of the International Air Transport Association (IATA) Dangerous Goods Regulations (DGR), which took effect on January 1, 2026, introduces updates to safely ship lithium batteries by air.
These batteries remain a major compliance concern due to the risk of thermal runaway and fires, and they’re scrutinized at every stage of the shipping process. A noncompliant shipment can lead to delays and penalties.
Lithium batteries’ shipping requirements aren’t a single set of rules but rather a matrix of regulations. This article will explain them in detail so shippers can confidently navigate the key changes in the 2026 IATA DGR regarding classification, packaging, labeling and documentation.
Determine Which Battery Rules Apply
The first step is to correctly classify your shipment as:
- Lithium-ion batteries, including UN 3480 and UN 3481
- Lithium-metal batteries, including UN 3090 and UN 3091
- Sodium-ion batteries, where relevant under current IATA battery provisions
- Batteries shipped alone, packed with equipment or contained in equipment
- Batteries installed in vehicles or other cargo transport units
The regulations vary based on several factors:
- Battery type: Lithium-ion batteries power most consumer electronics, such as mobile phones and laptops. Lithium-metal batteries are often used in devices like watches, calculators and key fobs. Generally, lithium-metal batteries face stricter regulations due to their distinct chemical composition.
- Larger battery type: These batteries are assigned UN numbers and have unique packaging and handling requirements due to their size and energy capacity. For example, a vehicle powered by a flammable liquid and a lithium-ion battery would be classified differently from a vehicle powered solely by a lithium-ion battery.
- Energy capacity: For lithium-ion batteries, this is measured in watt-hours (Wh). For lithium-metal batteries, this is measured in grams of lithium content. Smaller, lower-capacity batteries are subject to fewer restrictions and vice versa.
- How the battery is shipped: Stand-alone batteries face the most stringent regulations, then batteries packed with equipment and batteries contained in equipment.
- Aircraft type: Many types of lithium battery shipments are forbidden on passenger aircraft, but may be allowed on cargo-only aircraft, provided they meet all necessary requirements.
2026 State of Charge (SoC) Requirements
Stand-alone lithium-ion batteries (UN 3480 / PI 965) were already subject to strict 30% SoC limits. Effective January 1, 2026, the DGR converted previous guidance into a mandatory ≤30% SoC limit (or an indicated capacity display of ≤25%) for lithium-ion batteries packed with equipment (UN 3481 / PI 966) where the battery exceeds 2.7 Wh, as well as lithium-ion battery-powered vehicles (UN 3556 / PI 952) with batteries exceeding 100 Wh. The only exception to shipping above this threshold is obtaining an explicit waiver (Special Provision A331) from the State of Origin, the State of Operator, and relevant national authorities. This mandatory 30% SoC rule does not apply to lithium-metal batteries or to batteries permanently installed inside equipment (UN 3481 / PI 967), where a reduced SoC remains strongly recommended.
Packing Instruction Changes
Key packing instructions (PI) for lithium batteries include:
| PI Number | Description | Requirements |
| PI 965 | Stand-alone lithium-ion batteries | Shipments must be flown only on cargo aircraft, meet a 30% SoC limit and be accompanied by a Shipper’s Declaration for Dangerous Goods. |
| PI 966 | Lithium-ion batteries packed with equipment | SoC ≤ 30% for cells/batteries exceeding 2.7 Wh. |
| PI 967 | Lithium-ion batteries contained in equipment | A reduced SoC is not mandatory but strongly recommended for batteries, including those with an indicated battery capacity under 25%. |
| PI 952 / UN3556 | Lithium-Ion Vehicles | SoC ≤ 30% for vehicle batteries exceeding 100 Wh. |
| PI 968 | Lithium-metal batteries shipped alone | This PI mandates cargo-only aircraft, high-quality protective packaging and full documentation. |
| PI 969 and PI 970 | Lithium-metal batteries packed with or contained in equipment | This requires strong packaging and documentation, with the least restrictive rules under PI 970 applying when the battery is already contained inside a device. |
Packaging, Marks and Labels
These steps are crucial for safety and for ensuring your shipment is accepted by the carrier:
- Preventing movement and accidental activation
- Protecting battery terminals from short circuits
- Using appropriate inner and outer packaging
- Applying the lithium battery mark
- Applying the Class 9 lithium battery hazard label when required
- Using the “Cargo Aircraft Only” label in PI 965 and PI 968
- Maintaining package integrity
Note that the lithium battery mark isn’t a substitute for other required labels or documents.
Documentation and Shipper Responsibilities
The Shipper’s Declaration for Dangerous Goods, air waybill and other records must include:
- Correct UN number and proper shipping name: This tells handlers and emergency responders what they are dealing with.
- Packing instruction and authorization details: This declares which PI was followed and if the shipment is being made under a special approval.
- Net quantity and package count: These indicate the total amount of dangerous goods, which is essential for calculating weight and for risk assessment.
- SoC information, where applicable: With the IATA DGR 67th edition in effect, declaring that a shipment complies with the 30% SoC limit is a key safety measure.
- Availability of the UN 38.3 test summary: All lithium batteries must pass a series of safety tests, and the shipper must have the test summary on file.
- Accurate shipper and consignee information: The shipper is legally responsible for the shipment, and the consignee needs to know what they’re receiving. This contact information is also important in case of an emergency.
New and Clarified 2026 Provisions
The 2026 DGR also includes several new and clarified provisions. Passengers are advised not to charge their power banks or spare batteries using the aircraft’s in-seat power systems. These batteries are prohibited in checked baggage and must be carried in the cabin.
Data loggers and cargo tracking devices are now often exempt from the full scope of the regulations, provided they are in use or intended for use during transport, the battery meets certain size and testing requirements and the devices themselves are robust enough to withstand transport.
New UN numbers and proper shipping names have also been created for certain hybrid vehicles, including vehicles powered by flammable liquid or gas along with battery systems. Check for and comply with all applicable State and operator variations. Failure to do so can result in a shipment being rejected, even if you have followed the IATA rules.
Training and Competency Requirements
Training is required for all personnel involved in the shipping process, including those who:
- Classify or prepare lithium battery shipments: These individuals must be competent in determining the UN number and shipping name, following the right PI and understanding applicable requirements and exceptions.
- Pack, mark, label or document packages: These individuals need to correctly assemble packaging, protect batteries from short circuits, apply marks and labels in the proper locations and complete the necessary documentation.
- Sign the Shipper’s Declaration: This person’s training must be comprehensive, ensuring they have a thorough understanding of the entire process and can verify that the shipment is fully compliant before signing the declaration.
- Accept or handle dangerous goods cargo: Airline and ground-handling staff need to know how to identify correct and incorrect marking, labeling and documentation, and the procedures for handling damaged packages or discovering undeclared dangerous goods.
- Load, store or transport dangerous goods: These individuals’ training focuses on keeping certain dangerous goods away from others, loading procedures, emergency responses and the information that must be provided to the pilot-in-command.
Recurrent training must be completed within a 24-month cycle, but individual carriers, States or a company’s internal policy could require more frequent training.
Common Compliance Errors
Avoid these common mistakes:
- Using the wrong UN number
- Confusing “packed with” and “contained in” equipment
- Applying the wrong PI
- Shipping lithium-ion batteries above the permitted SoC
- Failing to protect terminals
- Omitting the required mark or label
- Assuming Section II means no compliance obligations
- Ignoring airline-specific variations
- Using outdated packaging or documentation
2027 Outlook
The 2026 DGR includes an “Impending Changes” appendix with potential updates for 2027, including those regarding hybrid battery systems and batteries in cargo transport units. As technology evolves, shippers may expect classification provisions for systems containing both lithium-ion and sodium-ion cells in a single battery. New UN numbers are also anticipated for large battery assemblies installed in cargo transport units, specifically for lithium-metal batteries.
Compliance Checklist for Lithium Battery Shippers
Use this checklist to confirm compliance with the lithium battery shipping regulations in 2026:
- Determine the correct UN number and shipping name.
- Ensure the SoC is within the new mandatory limits.
- Use the correct PI and ensure all requirements are met.
- Apply all required marks and labels.
- Complete necessary documentation accurately.
- Check for any State or operator variations that may apply.
- Ensure all personnel involved are properly trained.
Start Training Today With Hazmat School
The IATA DGR 67th edition introduces significant changes for shipping lithium batteries, and our courses can help your team understand the requirements for compliant shipments. Learn on your schedule with 24/7 access to instructors for any questions and receive your certification immediately upon passing.
Enroll in the Lithium Battery Ground & Air Shipping Course or the IATA Dangerous Goods Air Shipping Course today to stay ahead. You can also purchase a physical or digital copy of the IATA Dangerous Goods Regulations to complement your training.
Manages Hazmat School’s E-Learning courses and blog. Kirstie has extensive experience in the online training and education industry. Kirstie has worked with courses that offer a variety of safety and environmental certifications that satisfy OSHA, EPA and DOT requirements.
