Packing Instructions (PI)
Every dangerous good in IATA DGR is assigned a Packing Instruction (PI) number. The PI specifies what packaging types, quantities, and methods must be used. The PI number must be declared on the DGD (Shipper's Declaration).
PI Numbering System
Class 1 — Explosives
Special packaging instructions for explosive substances. Varies by subdivision and compatibility group.
Class 2 — Gases
Pressure cylinders, aerosols, and cryogenic containers. PI 200 general gases, PI 203 aerosols.
Class 3 — Flammable Liquids
Maximum inner packaging and package limits based on flash point and PG.
Class 4 — Flammable Solids
Separate PI series for subdivisions 4.1, 4.2, and 4.3.
Class 5 — Oxidizers & Organic Peroxides
Special rules for 5.1 oxidizers and 5.2 organic peroxides.
Class 6 — Toxic & Infectious
PI 620 (triple packaging) for 6.1 toxic and 6.2 infectious substances. PI 650 (Cat. B).
Class 8 — Corrosives
Inner packaging limits by PG and compatibility requirements.
Class 9 — Miscellaneous & Lithium Batteries
PI 965-970: Lithium batteries. PI 954: Dry ice. PI 956: Magnetized material.
How to Read a PI — Section I, Section II & Y-Limit
Many PIs (especially lithium battery PIs) are divided into Section I and Section II. The appropriate section is selected based on shipment quantity and conditions:
Section I
Fully regulated shipment. DGD required, UN packaging required, Class 9 hazard label required. Generally CAO only.
Section II
Simplified rules. No DGD required, no UN packaging required, no hazard label required. PAX and CAO permitted. Lower limits.
Y-Limit (Limited Quantity)
Simplest rules. Very small quantities. No DGD, no UN packaging, only Y-mark required. PAX + CAO.
Common Packing Instructions (29 PIs)
PAX/CAO maximum quantities, inner packaging limits, and special conditions
| PI | Substance / Class | Inner Pkg | PAX Max | CAO Max | Notes |
|---|---|---|---|---|---|
| PI 200 | Compressed gases (general)(2) | Per cylinder | Per division | Per division | 2.1: 1 kg PAX, 2.2: 75 kg PAX |
| PI 200 (2.3) | Toxic gases(2.3) | Per cylinder | FORBIDDEN | 25 kg | Strictly forbidden on PAX |
| PI 203 | Aerosols (UN 1950)(2.1/2.2) | 1 L (flammable) | 75 kg gross | 150 kg gross | Flammable/non-flammable distinction |
| PI 218 | Chemical oxygen generator(5.1) | — | FORBIDDEN | FORBIDDEN | Completely forbidden in air transport |
| PI 340 (PG I) | Flammable liquid, PG I(3) | 0.5 L | FORBIDDEN | 1 L | High hazard, PAX forbidden |
| PI 353 (PG II) | Flammable liquid, PG II(3) | 1 L glass/plastic | 1 L | 5 L | Most common PI |
| PI 353 (PG III) | Flammable liquid, PG III(3) | 5 L glass/plastic | 5 L | 60 L | Low hazard |
| PI 355 | Flammable liquid (low hazard)(3) | 30 L | 60 L | 220 L | PG III only, flash point >23°C |
| PI 445 (PG I) | Water-reactive, PG I(4.3) | 0.5 kg | FORBIDDEN | 1 kg | High hazard |
| PI 451 | Flammable solid, PG II(4.1) | 5 kg | 5 kg | 25 kg | General flammable solids |
| PI 504 | Organic peroxide, Type C-F(5.2) | 1 kg/L | 5 kg | 10 kg | Temperature control may be required |
| PI 508 (PG I) | Strong oxidizer, PG I(5.1) | 1 kg/L | FORBIDDEN | 2.5 kg | PAX forbidden |
| PI 508 (PG II) | Oxidizer, PG II(5.1) | 2.5 kg/L | 2.5 kg/L | 25 kg/L | |
| PI 602 (PG I inh.) | Highly toxic (inhalation), PG I(6.1) | 0.5 L | FORBIDDEN | 1 L | Inhalation toxicity, PAX forbidden |
| PI 602 (PG II) | Toxic, PG II(6.1) | 1 L/kg | 1 L/kg | 25 L/kg | |
| PI 602 (PG III) | Toxic, PG III(6.1) | 5 L/kg | 5 L/kg | 60 L/kg | |
| PI 620 | Infectious substance, Cat. A (UN 2814/2900)(6.2) | 50 mL/g | 50 mL/g | 4 L/kg | Triple packaging system required |
| PI 650 | Biological substance, Cat. B (UN 3373)(6.2) | 1 L (liquid) / 4 kg (solid) | 4 L/kg | 4 L/kg | No DGD required, outer package max 4 kg/4 L |
| PI 803 (PG I) | Strong corrosive, PG I(8) | 1 L/kg | FORBIDDEN | 2.5 L/kg | PAX forbidden |
| PI 803 (PG II) | Corrosive, PG II(8) | 1 L/kg | 1 L/kg | 30 L/kg | |
| PI 803 (PG III) | Corrosive, PG III(8) | 5 L/kg | 5 L/kg | 60 L/kg | |
| PI 954 | Dry ice (UN 1845)(9) | — | 200 kg | 200 kg | Check operator variations |
| PI 956 | Magnetized material (UN 2807)(9) | — | No limit | No limit | 0.00525 gauss distance requirement |
| PI 965 | Lithium ion battery (standalone)(9) | Cell: 20 Wh | Sec II: 5 kg | Sec I: 35 kg | Section II: no DGD required |
| PI 966 | Li-ion battery, packed with equipment(9) | Cell: 20 Wh | 5 kg | 35 kg | Packed with equipment |
| PI 967 | Li-ion battery, contained in equipment(9) | Cell: 20 Wh | 5 kg | 35 kg | Installed in equipment |
| PI 968 | Lithium metal battery (standalone)(9) | Cell: 1 g Li | Sec II: 2.5 kg | Sec I: 35 kg | Lower limits |
| PI 969 | Li-metal battery, packed with equipment(9) | Cell: 1 g Li | 5 kg | 35 kg | Packed with equipment |
| PI 970 | Li-metal battery, contained in equipment(9) | Cell: 5 g Li | 5 kg | 35 kg | Installed in equipment |
Lithium Battery PI Details — Section I vs Section II
PI 965-970: Section I (fully regulated) vs Section II (simplified) comparison
| Topic | Section I | Section II |
|---|---|---|
| DGD required? | YES | NO |
| UN packaging required? | YES | NO |
| Class 9 hazard label | YES | NO |
| Lithium battery mark | NO (label used instead) | YES (PI 966-970 Sec II) |
| PAX aircraft | Only 967/970 (in equipment) | YES (all) |
| CAO aircraft | YES | YES |
| Li-ion cell limit | > 20 Wh allowed (max 100 Wh) | ≤ 20 Wh |
| Li-ion battery limit | > 100 Wh allowed (max 12 kg standalone) | ≤ 100 Wh |
| Li-metal cell limit | > 1 g Li allowed (max 2 g) | ≤ 1 g Li |
| Li-metal battery limit | > 2 g Li allowed (max 12 kg standalone) | ≤ 2 g Li |
| Max weight per package | CAO: 35 kg | 2.5 kg (968), 5 kg (965) |
| SoC (State of Charge) | ≤ 30% (965/968 Sec I) | No restriction |
Inner & Outer Packaging Types
Common packaging types found in PIs and permitted combinations
Inner Packaging
- • Glass: 1A — max 1 L (PG I), 2.5 L (PG II-III)
- • Plastic: 1H — max 1-5 L, chemical compatibility required
- • Metal: 1B — max 1-5 L, generally for solvents
- • Earthenware: max 0.5 L, PG I liquids
- • Fiberboard: solids only, 5 kg max
Outer Packaging
- • 4G Fiberboard box: Most common, lightweight, economical
- • 4C1/4C2 Plywood box: Heavy loads
- • 1A2 Steel drum: Liquids, high protection
- • 1H2 Plastic drum: Corrosive substances
- • Combination packaging: Inner + outer mandatory combination
Performance Standard: X = PG I-II-III compatible (highest), Y = PG II-III compatible, Z = PG III only. UN-approved packaging meeting the minimum performance standard specified in the PI must be used.
PI Content Structure
Each PI contains the following information:
- - Permitted packaging types (inner and outer packaging)
- - Maximum quantity per inner packaging
- - Maximum net quantity per outer packaging (PAX and CAO separately)
- - Special packaging requirements (e.g., pressure resistance, leak-proofness)
- - Y-limit quantities (for limited quantities)
- - Applicable State and Operator Variations
Important Notes
- - PIs marked as FORBIDDEN cannot be transported on passenger aircraft (PAX) under any circumstances.
- - Table limits are maximum quantities per package. Operator variations may impose lower limits.
- - The “Forbidden” entry in Table 4.2 indicates the substance cannot be transported on that aircraft type.
- - Some PIs include special conditions (temperature control, ventilation, segregation, etc.).
- - For definitive PI information, consult DGR Table 4.2.