Shipping Lithium Batteries by Air?
One Wrong UN Number Grounds Your Cargo.
Lithium batteries are the most rejected dangerous goods category in air freight. AÉRO-DG classifies your shipment correctly - UN3480, UN3481, UN3090, or UN3091 - packs it to the right instruction, and prepares airline-ready documentation so it clears YYZ the first time.
Standalone Lithium Ion Batteries Are Forbidden on Passenger Aircraft.
UN3480 shipments must move cargo-only, at a state of charge no higher than 30%, under the correct packing instruction. Miss any one of those and the airline issues a rejection - your freight sits, your customer waits, and re-booking costs multiply. We make sure none of that happens.
The Four Lithium Battery UN Numbers
Every lithium battery shipment falls under one of four UN numbers. Which one applies decides your packing instruction, your documentation, and whether your cargo can fly on a passenger aircraft at all.
| UN Number | What It Covers | Passenger Aircraft |
|---|---|---|
| UN3480 | Lithium ion batteries shipped on their own (power banks, EV modules, BESS packs, replacement batteries) | Forbidden - cargo aircraft only, max 30% state of charge |
| UN3481 | Lithium ion batteries packed with equipment or contained in equipment (laptops, tools, medical devices) | Permitted within IATA DGR limits |
| UN3090 | Lithium metal batteries shipped on their own (non-rechargeable cells, backup batteries) | Forbidden - cargo aircraft only |
| UN3091 | Lithium metal batteries packed with equipment or contained in equipment | Permitted within IATA DGR limits |
Watt-Hour & Lithium Content, Explained
Every classification decision traces back to two numbers: watt-hour rating for lithium ion batteries, and lithium metal content for lithium metal batteries. Transport Canada requires the watt-hour rating printed on the case for any battery manufactured on or after January 1, 2009 - if it's missing, full TDG requirements apply with no exceptions.
Lithium Ion - Watt-Hours
Wh = V × Ah
Wh = V × (mAh ÷ 1000)
Example: a 3.7V, 2600mAh cell → 3.7 × (2600 ÷ 1000) = 9.62 Wh.
Lithium Metal - Lithium Content
g = Ah × 0.3
g = (mAh ÷ 1000) × 0.3
The × 0.3 factor is a common estimate only - the actual lithium content is a design value from the manufacturer's UN 38.3 test summary, which we confirm before classifying. For multi-cell batteries, multiply single-cell lithium content by the number of cells.
Formulas per Transport Canada's lithium battery shipping guidance. We calculate and verify both figures as part of every classification we prepare.
Batteries That Cannot Fly - Under Any Classification
Damaged, defective, recalled, or recycled batteries are forbidden on aircraft, full stop. Transport Canada is explicit on this - it doesn't matter whether the battery is standalone, packed with equipment, or contained in a device. There is no packing instruction, no exemption, and no declaration that makes a damaged or recalled battery airworthy. These require specialized hazmat disposal handling instead.
Counterfeit batteries are a real, growing risk
Before importing lithium batteries, Transport Canada advises verifying they aren't counterfeit and confirming they carry documented proof of testing to UN Manual of Tests and Criteria standards - the same eight-test battery of standards every legitimate lithium cell design must pass. No-brand or low-quality batteries frequently skip this testing entirely, carry poor internal protection, and are far more prone to overheating and thermal runaway - a fire that's difficult to extinguish and spreads to nearby cells.
We verify UN 38.3 test summary documentation and manufacturer proof of compliance before we classify or pack any lithium battery shipment - for both exporters and importers.
What AÉRO-DG Does for Battery Shippers
Classification & Packaging
- → Confirm correct UN number and packing instruction
- → Section II vs Section I determination
- → UN-certified packaging supply and physical packing
- → Lithium battery marks, Class 9 labels, CAO labels
Documentation & Compliance
- → IATA Shipper's Declaration preparation
- → State of charge verification (30% rule for UN3480)
- → UN 38.3 test summary review
- → BESS and large-format module consulting
Serving EV exporters, electronics manufacturers, and energy storage companies across the GTA. Same-day service available for urgent YYZ shipments - call us directly.
How It Works
Send us battery details
Battery type, watt-hour rating or lithium content, quantity, whether packed with or in equipment, and destination. WhatsApp or email - we respond within 2 hours.
We classify & pack
Our IATA-certified team confirms the UN number, Section I or II status, and packing instruction, then packs and marks the shipment to spec.
Receive airline-ready cargo
Fully documented, labelled, and packed shipment ready for tender at the YYZ cargo counter - with a signed Shipper's Declaration where required.
Lithium Battery Shipping Questions
What is the difference between UN3480 and UN3481?
UN3480 covers lithium ion batteries shipped on their own. UN3481 covers lithium ion batteries packed with equipment or contained in equipment. The distinction changes the packing instruction, state of charge limits, and whether the shipment can move on passenger aircraft.
Can lithium batteries be shipped on passenger aircraft?
Standalone lithium ion batteries (UN3480) and standalone lithium metal batteries (UN3090) are forbidden on passenger aircraft and must move cargo-only. Batteries packed with or contained in equipment (UN3481, UN3091) may qualify for passenger aircraft, subject to quantity and packing limits under the IATA DGR.
What is Section II lithium battery packaging?
Section II historically allowed simplified handling for smaller lithium batteries. Which shipments still qualify depends on the UN number and the current IATA DGR edition - eligibility for batteries shipped on their own has narrowed in recent editions, and getting it wrong is one of the most common causes of airline rejections. We confirm the applicable section and rule against the current edition for your specific shipment.
Do lithium batteries need a state of charge limit for air transport?
Yes. Standalone lithium ion batteries (UN3480) must be shipped at a state of charge not exceeding 30% under the IATA DGR. We verify state of charge requirements as part of every lithium battery shipment we prepare.
Can AÉRO-DG handle battery energy storage systems (BESS)?
Yes. We prepare classification and documentation for battery energy storage system shipments, including large-format lithium ion modules and rack systems, which carry their own requirements under the IATA DGR and Transport Canada TDG regulations.
Can damaged, defective, or recalled lithium batteries be shipped by air?
No. Transport Canada is explicit that damaged, defective, recalled, or recycled batteries are forbidden on aircraft under any circumstances, regardless of whether they're standalone or contained in equipment. These require specialized hazmat disposal or ground transport handling instead - we can advise on the correct path.
How do I calculate a battery's watt-hour rating for shipping?
Watt-hours equal voltage multiplied by amp-hours (Wh = V × Ah), or voltage multiplied by milliamp-hours divided by 1000 (Wh = V × (mAh ÷ 1000)). Transport Canada requires this rating printed on the battery case for units manufactured after January 1, 2009. We calculate and verify this for every shipment as part of classification.
Guidance summary only. Lithium battery air transport rules change with each annual IATA DGR edition. UN numbers, section eligibility, state-of-charge limits, and packing instructions on this page are provided for general orientation and do not replace a formal classification. We verify the current edition's requirements against your specific shipment before it is tendered. Last reviewed 2026-07.
Ship Your Batteries Right the First Time
One misclassified battery shipment costs more in delays and re-booking than proper compliance ever will. Send us your battery specs and we'll tell you exactly what your shipment needs.