Strict dangerous goods regulations apply to air freight transport of a lithium-ion battery.

These are the most important points you must observe:

• Classification as dangerous goods (Class 9): Batteries over 100 Wh must always be classified as Class 9 dangerous goods and are subject to the comprehensive dangerous goods regulations of the IATA DGR and ICAO TI.

• Air freight only approval: Batteries above 100 Wh may only be shipped on cargo aircraft, not passenger aircraft. Freight forwarders do not handle dangerous goods shipments for private individuals. Therefore, it is often advisable to purchase a new battery locally if, for example, you move abroad and wish to take your bicycle or golf trolley battery with you.

• Maximum state of charge 30 %: Since April 2016, lithium-ion batteries (UN 3480) as standalone batteries may only be transported with a state of charge not exceeding 30 %. From 2026, this requirement will also apply to batteries installed in equipment.

• UN test summary (UN 38.3 test): A test summary must be available and presented upon request throughout the supply chain. This confirms that the battery has passed the UN transport safety tests.

• Packing instructions:

• • Requirements according to Packing Instruction PI 965 Part I A (without equipment).
  • The packaging must be UN-certified, shock-resistant, and leak-proof.
  • Each package must be clearly marked with the appropriate dangerous goods label, UN number (UN 3480 for standalone batteries, UN 3481 for batteries packed with or in equipment), and any additional labels.

• Accompanying documents: A dangerous goods transport document containing all relevant information (e.g., UN number, proper shipping name, class, packing instruction, shipper/consignee, state of charge) must accompany the shipment.

• Quantity limitations: For larger batteries, additional restrictions apply to the permissible net quantity per package (usually 35 kg per package).

• Defective or damaged batteries: Must not be transported by air and must be disposed of separately.

• Training requirement: As a shipping company, you are required to employ trained personnel for marking, packing, and documentation. The training (two days) includes an examination.

Additional notes:

• Many express and courier services refuse to transport batteries of this size or accept them only under very limited conditions.
• Compliance with and proof of the state-of-charge limit may already be required for current shipments.

Conclusion: You must arrange transport through an experienced dangerous goods forwarder, fulfill all documentation and marking requirements, reduce the state of charge to a maximum of 30 %, provide the UN 38.3 test summary, and pack the battery according to PI 965 Part I A. Otherwise, you face legal consequences, fines, or loss of insurance coverage.