Air transport of lithium batteries is subject to strict safety rules due to their potential fire risk, which can affect how they must be packed, labelled, and transported. Depending on the type and quantity of batteries, some shipments may be restricted from travelling on passenger aircraft and require specific packaging and documentation. Because these limitations can lead to delays or reduced transport options, the AAD encourages using sea transport pathways whenever practical. When air transport is necessary, consignors must follow the outlined requirements to ensure shipments can be accepted and moved safely.

Transport of lithium batteries by air is strictly regulated under the International Air Transport Association (IATA) Dangerous Goods Regulations. These regulations are in place because lithium batteries present a significant fire risk during air transport, particularly if damaged, defective, or at a high state-of-charge (SoC).

Depending on the size and total quantity of batteries in your shipment, the required packaging and labelling may vary. This may restrict the consignment from travelling on passenger aircraft, or it may need to be repacked by the AAD’s Dangerous Goods team to ensure compliance with applicable regulations. Reach out to the Dangerous Goods team if you have any concerns.

If a consignment cannot be transported on passenger aircraft, it must travel as Cargo Aircraft Only (CAO). CAO shipments cannot travel on the AAD’s A319 passenger flights or on C17 flights carrying expeditioners, which means available cargo‑only flight options may be limited and subject to change at short notice. As a result, delays may occur, and some consignments may be unable to travel.

The AAD strongly recommends using sea transport pathways for lithium batteries and battery‑operated equipment, as sea freight is not subject to the same limits on battery quantity or state‑of‑charge. When sea transport is not possible, please ensure your shipment meets the delivery and packaging requirements outlined below.

General Requirements

  • Lithium-ion batteries must be shipped with indicated battery capacity (the level shown on the device’s display or battery indicator) not exceeding 25%. A state-of-charge declaration confirming compliance must be signed by the consignor, a copy can be downloaded from the link at the bottom of this page.
  • Batteries must be protected from short circuit, typically by placing each battery in an inner package that fully encloses it (e.g., a zip‑lock bag or small box).
  • Outer packaging must be strong and rigid, suitable for the type of equipment or batteries being shipped. Where possible, please leave batteries and equipment in original manufacturer packaging. 
  • Packages must prevent shifting, contact, or accidental activation of batteries or equipment.
  • Maximum weight limits apply to battery shipments, please reach out to the DG team if your consignment contains more that 5 kg of batteries per package. 
  • Damaged or defective batteries, or batteries being shipped for recycling or disposal are forbidden from air transport and must be transported via sea cargo pathways. Please keep this in mind, particularly when returning equipment to Australia, and check that all batteries are free from damage.

Additional Requirements

Loose lithium batteries
(Consignments including batteries only, no equipment):

  • Not permitted on passenger aircraft and must be transported as Cargo Aircraft Only (CAO).

Lithium batteries packed with equipment
(Batteries packaged in the same box as the equipment they power but not installed)

  • The number of batteries in each package must not exceed the number required for the equipment’s normal operation, plus two spare sets

Lithium batteries contained in equipment
(Batteries installed within the equipment)

  • Must be packed in a strong, rigid outer package, unless the equipment is large and inherently provides sufficient protection. In such cases, the equipment may be transported unpackaged or palletised.

If you have any questions please contact DangerousGoods@aad.gov.au

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