Lithium Battery Guide
Transport rules for lithium ion (Li-ion) and lithium metal (Li-metal) batteries by air. PI 965-970 instructions, Section I vs Section II distinctions, SoC limits, and packaging requirements.
Thermal Runaway Risk
Lithium batteries can cause fire or explosion due to thermal runaway. Damaged, defective, or recalled lithium batteries are STRICTLY FORBIDDEN in air transport.
Standalone (Battery Only)
Battery shipped without equipment. Strictest rules apply.
PI 965 / PI 968
Packed with Equipment
Battery and equipment in the same package, but battery not installed.
PI 966 / PI 969
Contained in Equipment
Battery installed inside the equipment. Most flexible rules.
PI 967 / PI 970
Li-ion vs Li-metal — Key Differences
| Property | Lithium Ion (Li-ion) | Lithium Metal (Li-metal) |
|---|---|---|
| UN Numbers | UN 3480 (standalone), UN 3481 (with/in equipment) | UN 3090 (standalone), UN 3091 (with/in equipment) |
| Rechargeable | Yes — rechargeable | No — primary (non-rechargeable) |
| Rating Unit | Watt-hours (Wh) | Lithium content (g) |
| Section II Cell Limit | ≤ 20 Wh per cell | ≤ 1 g Li per cell |
| Section II Battery Limit | ≤ 100 Wh per battery | ≤ 2 g Li per battery |
| Section IB Cell Limit | > 20 Wh but ≤ 35 Wh per cell | > 1 g but ≤ 5 g Li per cell |
| Section IB Battery Limit | > 100 Wh but ≤ 36000 Wh | > 2 g Li |
| Sec II Max Weight (standalone) | 5 kg net/package | 2.5 kg net/package |
| Common Examples | Smartphones, laptops, power banks, e-bikes | Watch batteries, coin cells, non-rechargeable medical devices |
| Packing Instructions | PI 965, PI 966, PI 967 | PI 968, PI 969, PI 970 |
PI 965-970 Detail Table
Fully regulated, DGD required
PAX: Some operators FORBIDDEN | CAO: 35 kg net/package
Simplified, no DGD required
PAX: 5 kg net/package | CAO: 5 kg net/package
Limit: <=20 Wh/cell, <=100 Wh/battery
Fully regulated, DGD required
PAX: 5 kg | CAO: 35 kg
Simplified
PAX: 5 kg | CAO: 5 kg
Limit: <=20 Wh/cell, <=100 Wh/battery
Fully regulated, DGD required
PAX: 5 kg | CAO: 35 kg
Simplified
PAX: 5 kg | CAO: 5 kg
Limit: <=20 Wh/cell, <=100 Wh/battery
Fully regulated, DGD required
PAX: Some operators FORBIDDEN | CAO: 35 kg net/package
Simplified, no DGD required
PAX: 2.5 kg net/package | CAO: 2.5 kg net/package
Limit: <=1 g Li/cell, <=2 g Li/battery
Fully regulated, DGD required
PAX: 5 kg | CAO: 35 kg
Simplified
PAX: 5 kg | CAO: 5 kg
Limit: <=1 g Li/cell, <=2 g Li/battery
Fully regulated, DGD required
PAX: 5 kg | CAO: 35 kg
Simplified
PAX: 5 kg | CAO: 5 kg
Limit: <=1 g Li/cell, <=2 g Li/battery
Section I vs Section II Comparison
| Feature | Section I | Section II |
|---|---|---|
| DGD Required? | YES — Full DGD mandatory | NO — DGD not required |
| CAO Label | YES (for CAO shipments) | NO |
| Lithium Battery Mark | YES | YES |
| Class 9 Hazard Label | YES | NO |
| UN 3480/3090 Marking | YES | YES (on lithium battery mark) |
| SoC (State of Charge) | No restriction (per PI) | <= 30% SoC (PI 965/968) |
| UN 38.3 Testing | YES | YES |
| Overpack Rules | Standard overpack rules | Overpack: 'Overpack' + Li battery mark |
State of Charge (SoC) Rules
PI 965 / PI 968 — Section II (Standalone Batteries)
State of Charge must not exceed 30% of rated capacity. This rule applies to standalone batteries shipped under Section II only. The 30% SoC requirement significantly reduces thermal runaway risk during transport.
PI 966-967 / PI 969-970 (With or In Equipment)
No SoC restriction applies when batteries are packed with or contained in equipment. However, the equipment must be protected against accidental activation, and the battery must be protected from short circuit.
Section I — All PIs
Section I shipments of standalone batteries (PI 965/968) must also comply with the 30% SoC limit. Section I batteries packed with or in equipment (PI 966-967 / PI 969-970) have no SoC restriction.
PAX vs CAO Restrictions
Passenger Aircraft (PAX)
- - PI 965 Section I: FORBIDDEN by most operators
- - PI 968 Section I: FORBIDDEN by most operators
- - PI 966/967 Section I: Permitted, max 5 kg net
- - PI 969/970 Section I: Permitted, max 5 kg net
- - All Section II: Permitted within stated limits
Cargo Aircraft Only (CAO)
- - PI 965/968 Section I: Max 35 kg net/package
- - PI 966-967, 969-970 Section I: Max 35 kg net/package
- - All Section II: Permitted within stated limits
- - CAO label required for Section I shipments
- - Accessible to crew, notification to pilot-in-command
Important Notes
- - UN 38.3 test report is MANDATORY for all lithium batteries.
- - Section II standalone batteries: maximum 2 batteries per package (PI 965/968).
- - SoC (State of Charge): maximum 30% charge level for PI 965/968 standalone shipments.
- - E-bike / e-scooter batteries are generally above 100 Wh, therefore fall under Section I.
- - Pay special attention to operator variations — many airlines do not accept PI 965 Section I on PAX aircraft.
- - Each cell and battery must be individually protected against short circuit (e.g., tape over terminals, individual plastic bags).