Michael Turner
Regulatory snapshot: U.S. and international rules (TSA/FAA/IATA) prohibit spare lithium-ion and lithium-metal cells from the aircraft hold; those spares must travel in the cabin. Lithium‑ion cells up to 100 Wh are permitted in carry‑on without airline approval; cells between 100–160 Wh require airline approval and are typically limited to two spares per passenger. Lithium‑metal cells are limited to 2 g lithium content per cell and are allowed in the cabin only. Devices with installed lithium cells are generally accepted in either location, but carriers prefer they remain in the cabin.
Packing guidance for alkaline/primary cells (AA, AAA, C, D, 9V): these cells are normally acceptable both in cabin and in the aircraft hold. Prevent short circuits by taping exposed terminals, keeping cells in original retail packaging, or using dedicated plastic cases. Whenever possible, install cells inside the device rather than shipping loose; cover 9V terminals with tape or a terminal cap.
Power banks, spare packs and e‑cigarette cells: portable chargers and spare power packs are classified as lithium‑ion spares and must be carried in the cabin. Check the Wh rating printed on the pack: under 100 Wh is routinely allowed in carry‑on; between 100–160 Wh needs airline approval; above 160 Wh is usually forbidden for passenger carriage. Do not place power banks or spare cells in the aircraft hold.
Mobility aids and large batteries: wheelchairs and medical equipment containing wet, sealed or lithium cells require advance airline notification and specific preparation (terminal protection, secure mounting, documentation of Wh or lithium content). Some carriers will accept installed large batteries in the hold with prior approval and special packaging; confirm policies with the airline well before travel.
Quick checklist: verify Wh or lithium‑gram rating on each cell; keep all spares in carry‑on if lithium chemistry; tape or cap terminals; retain original packaging or use plastic cases; contact the carrier when any cell exceeds 100 Wh or when transporting batteries for mobility/medical devices.
Are alkaline (AA/AAA/C/D) and NiMH rechargeable cells permitted in aircraft hold?
Yes – alkaline AA/AAA/C/D cells and NiMH rechargeable cells are generally permitted in the aircraft hold when packed to prevent short circuits and damage.
Packing recommendations
Store spare cells in original retail packaging or in non-conductive plastic cases; cover exposed terminals with tape or use terminal caps. Installed cells may remain inside equipment, but the device must be powered off and protected against accidental activation. Keep cells separated from metal objects (coins, keys, loose tools). For large numbers, use manufacturer boxes or purpose-built battery cases.
Exceptions and operational notes
Do not transport leaking, damaged, modified, or recalled cells; such items are prohibited from air transport. Commercial shipments or quantities intended for resale usually require dangerous-goods documentation and carrier approval. Airline-specific restrictions vary – verify carrier policies before travel. Lithium-based cells follow different rules and are subject to stricter carriage requirements.
Keep spare loose cells in the cabin; do not stow them in the aircraft hold
Store all spare loose cells in carry-on bags so cabin crew can access and respond to any thermal event; never place spares in the aircraft hold.
Packing recommendations
Insulate each cell’s terminals with non-conductive tape or use rigid plastic cases; original manufacturer packaging is acceptable. Place insulated cells in a dedicated pocket or small hard-sided container, separated from metal objects, coins and charging cables. Avoid loose placement in clothing or open compartments; keep spares accessible for security screening.
Limit quantities to what is needed for personal devices. For coin, alkaline-type and NiMH cells, keep them in retail packaging or individual cases to prevent short circuits. For cell packs (power banks), ensure external markings show watt-hour (Wh) rating and carry them only in the cabin.
Watt‑hour and airline rules (lithium cells)
Lithium‑ion cell guidance: cells up to 100 Wh are generally allowed in the cabin without airline approval; cells between 100 Wh and 160 Wh require airline approval and are usually limited to two spare units per passenger; cells above 160 Wh are prohibited on passenger aircraft. Always verify the Wh marking on each pack and present packs separately during screening when requested.
When uncertain about limits or quantity allowances, consult the carrier before travel and declare spare cells at check-in if required. For unrelated travel suggestions, see best aquarium in phoenix.
Prevent short circuits by insulating and packing cell terminals for aircraft hold
Insulate all exposed terminals with non-conductive tape and store each cell in an individual hard plastic case or original retail blister before stowing in a suitcase bound for the aircraft hold.
Recommended materials
- Electrical tape (PVC) or Kapton tape – single-use strips to cover terminals fully.
- Commercial terminal caps or snap-on plastic covers for 9V and larger cylindrical cells.
- Hard plastic battery cases or multi-cell foam inserts (transparent polypropylene or ABS cases preferred).
- Clear zip-top plastic bags for grouping already-cased cells (avoid allowing terminals to touch within).
- Small rigid box (plastic or cardboard) to contain cased groups and prevent movement inside a suitcase.
Step-by-step packing procedure
- Inspect each cell: discard any with dents, leakage, corrosion or bulging. Do not attempt to reuse damaged cells.
- Clean terminals of dirt or film with a dry cloth; avoid solvents.
- Apply tape: cut a strip long enough to wrap the positive terminal plus a small section of the cell body. Press tape edges to seal. Repeat for negative terminal if exposed. For coin cells, cover both sides so metal faces cannot contact conductive surfaces.
- Use terminal caps for 9V and large cylindrical cells when available; otherwise use a full-wrap tape method covering the snap or post connectors completely.
- Place each insulated cell in its own plastic case or original retail packaging. Do not allow two insulated terminals to touch each other even inside the same bag.
- Group cased cells in a clear zip-top bag or small rigid box; cushion with foam or clothing to prevent shifting. Maintain separation between different chemistries (alkaline, NiMH, Li-ion) using dividers or separate bags.
- Put the box in the center of the suitcase, surrounded by soft items (clothing) and away from metal objects such as coins, keys, tools or electronics that could breach insulation.
- Secure the box lid with tape so it cannot open during handling. Attach a brief paper label: “Terminals insulated – cells inside.” Keep a packing list with the bag for inspection purposes.
- For rechargeable packs with exposed bus bars or external terminals: insulate each terminal with tape, enclose the pack in a non-conductive sleeve, and place inside a hard-case container to prevent pressure or deformation.
Do not rely on loose tape alone without a hard container; movement and abrasion during transit can abrade tape layers and lead to contact with metal items.
Airline and country limits: quantity limits for alkaline and NiMH cells in the aircraft hold
Recommendation: limit alkaline and NiMH cells in hold bags to 48 AA-equivalents per passenger; if carrying more than ~50–100 cells, contact the carrier in advance and expect possible declaration or conversion to cargo shipment.
United States – TSA guidance does not set a numeric ceiling for household dry cells in hold or cabin; major US carriers (American, Delta, United) similarly provide no passenger-level count limit for household cells, but large quantities can trigger inspection or require airline approval.
European Union / IATA – IATA Dangerous Goods Regulations do not treat standard alkaline or NiMH cells as dangerous for passenger baggage in retail quantities; national aviation authorities generally follow this approach and have no fixed numeric limit for personal quantities. Commercial or bulk shipments require airline acceptance and DGR handling.
United Kingdom and Australia – Civil Aviation Authority and CASA guidance align with IATA: typical personal quantities are permitted without a numeric cap, while quantities that resemble commercial consignments (dozens to hundreds) should be cleared with the airline.
Middle East & other regions – Major carriers (Emirates, Qatar Airways, Etihad) allow household cells in hold bags under regular passenger rules; regional variations exist, so confirm with the airline when planning to travel with more than ~50 cells.
| Carrier | Official guidance (household cells) | Suggested per-passenger cap for hold bags |
|---|---|---|
| American Airlines | No specific passenger numeric limit; subject to security screening | 48 AA-equivalents |
| Delta Air Lines | Household dry cells permitted; no stated count limit for passengers | 48 AA-equivalents |
| United Airlines | Household cells allowed in hold or cabin; large quantities require approval | 48 AA-equivalents |
| British Airways | Follow IATA/CAA guidance for household cells; contact BA for large volumes | 48 AA-equivalents |
| Lufthansa | Household cells allowed; commercial quantities need airline handling | 48 AA-equivalents |
| Qantas | Follows IATA; declare bulk quantities to carrier | 48 AA-equivalents |
| Emirates | Household cells allowed under normal passenger rules; verify for high counts | 48 AA-equivalents |
| Air France | Household cells permitted; airline approval recommended for large quantities | 48 AA-equivalents |
Operational tips: label boxes if transporting multiple identical packs, keep commercial invoices for quantities over a few dozen, and contact the airline or national aviation authority at least 48 hours before departure for any shipment that approaches commercial scale.
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Steps if a power cell leaks, overheats or is damaged in aircraft hold
Immediate actions
Isolate smoking, hot or leaking power cells immediately by moving the affected item into a metal or ceramic container placed outdoors or in a well‑ventilated area; maintain at least 5 m distance from textiles, paper and fuel sources.
Wear nitrile gloves, eye protection and a respirator (N95 or higher) before handling. Avoid direct skin or eye contact; if electrolyte contacts skin or eyes, rinse with running water for 15 minutes and seek medical attention.
If visible flames are small and controllable use water to cool and suppress lithium‑ion thermal events; for lithium‑metal fires use a Class D powder extinguisher. For any fire that is spreading or producing heavy smoke, evacuate the area and contact emergency services immediately.
Follow‑up and disposal
Do not transport damaged, leaking or smoking power cells on board an aircraft. Notify airline ground staff or the check‑in agent at the earliest opportunity and hand the item to the airline’s hazardous‑materials team or an authorized handler for removal and safe disposal.
Document the incident: take photos of the device, visible damage, serial/model numbers and retain baggage tags and boarding information. Provide these to airline staff and, if requested, to the local aviation authority.
For transport to an authorized disposal facility, place the damaged cell in a sealed, non‑reactive container with inert absorbent (vermiculite, sand); tape exposed terminals to prevent short circuits and label the container “damaged/leaking power cell – hazardous.” Deliver only to a certified electronic waste or hazardous‑waste facility; do not discard in regular municipal trash.
If discovery occurs in flight (smell of smoke, cabin indications), inform cabin crew immediately; crew will coordinate with the flight deck and ground emergency response according to airline procedures.
