Michael Turner
Keep all lithium-ion power packs in cabin baggage; do not stow them in the aircraft hold. Spare cells/packs carried separately are forbidden from being placed in hold storage because of fire risk; units installed inside equipment may be permitted but are best transported in the cabin when feasible.
Regulatory limits: most operators follow IATA/FAA guidance. Units up to 100 Wh are allowed in carry-on without prior approval. Units between 100 Wh and 160 Wh require airline approval and are typically limited to two items per passenger. Items above 160 Wh are not permitted on passenger aircraft, neither in the cabin nor in the hold.
How to verify rating: look for a watt‑hour (Wh) marking. If only milliamp-hours (mAh) and voltage (V) are shown, calculate Wh = V × Ah (Ah = mAh ÷ 1000). Examples: 5,000 mAh at 3.7 V ≈ 18.5 Wh; 10,000 mAh ≈ 37 Wh; 20,000 mAh ≈ 74 Wh; 30,000 mAh ≈ 111 Wh (this one falls into the 100–160 Wh band and needs approval).
Packing and handling: protect terminals (cover with tape or keep in original retail packaging), switch units off, and place each pack in a separate plastic pouch or protective case. Do not pack loose spare cells/packs in checked baggage or in the aircraft hold. Declare items to airline staff when requested and follow any carrier-specific documentation or labeling requirements.
Simple preflight checklist: 1) verify Wh rating; 2) confirm carrier policy for 100–160 Wh items and obtain approval if required; 3) protect terminals and stow in carry-on; 4) remove packs from checked suitcases or hold cargo before travel.
Storage rules for external USB power packs on flights
Answer: Store external USB power packs in hand baggage only; do not place them in the aircraft hold due to fire risk and regulatory prohibitions.
Regulatory limits: International aviation bodies permit energy packs under 100 Wh in cabin without prior approval. Units between 100 Wh and 160 Wh require airline approval and are normally limited to two per passenger. Units exceeding 160 Wh are not permitted on passenger aircraft in any location.
How to verify rating: If only mAh is printed, convert to watt‑hours: Wh = (mAh ÷ 1000) × V. Most lithium‑ion cells use 3.7 V. Practical examples: 5,000 mAh ≈ 18.5 Wh; 10,000 mAh ≈ 37 Wh; 20,000 mAh ≈ 74 Wh; 26,800 mAh ≈ 99.2 Wh.
Packing checklist: switch the unit off; fit terminal covers or tape exposed contacts; keep in original packaging if available; carry proof of Wh rating (label or spec sheet); declare any unit in the 100–160 Wh band to the airline before departure; place among carry‑on items where security staff can inspect.
Enforcement and risks: Security screening may remove unauthorized packs from hold, confiscate them, or deny boarding. Some carriers levy fines for non‑compliant carriage. When in doubt, contact the airline with the model and rated Wh.
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TSA and IATA guidance: are power packs allowed in the aircraft hold?
Recommendation: Store external lithium‑ion power packs in cabin/carry‑on only; spare cells and standalone power units are not permitted in the aircraft hold under TSA and IATA rules.
TSA specifics
TSA classifies spare lithium‑ion cells and power packs as prohibited in the aircraft hold. Devices with installed lithium‑ion cells may be transported in hold baggage subject to airline policy, but placement in the cabin is preferred. Watt‑hour thresholds: units ≤100 Wh are accepted in cabin without airline approval; units >100 Wh and ≤160 Wh require airline approval and are normally limited to two spare units per passenger; units >160 Wh are forbidden on passenger aircraft unless shipped as regulated cargo. Terminals must be protected against short circuit (original packaging, terminal covers, or tape); each unit should be isolated from metal objects.
IATA specifics and practical steps
IATA DGR treats lithium‑ion cells/packs under UN3480/UN3481. Spare cells/packs must be carried in the cabin; cells packed with or contained in equipment have separate provisions and may be accepted in the hold only if operator acceptance, correct packaging/labeling and DGR requirements are met. Actions: verify the Wh rating printed on the unit or calculate Wh = V × Ah (example: 3.7 V × 10,000 mAh = 37 Wh); keep units in original packaging or in individual protective sleeves; insulate terminals; limit quantity per operator rules; obtain airline approval for 100–160 Wh units and always notify the carrier when required. Units >160 Wh require dangerous‑goods shipment and are generally not permitted on passenger flights.
Capacity limits (Wh): what ratings typically permit or prohibit carriage in the aircraft hold
Recommendation: Do not place Li‑ion cells or power packs above 100 Wh in the aircraft hold; units between 100 Wh and 160 Wh require explicit airline/operator approval (usually limited to two packs per passenger) and are normally barred from the hold; packs over 160 Wh are not allowed on passenger flights except via approved cargo/freighter arrangements with special documentation and packing.
- ≤100 Wh: Generally accepted for passenger travel. Installed packs inside equipment may in some cases be stowed in the aircraft hold at the operator’s discretion; spare packs are typically restricted to the cabin. Carrier policies vary on quantity allowed per person.
- 100–160 Wh: Airline/operator approval required before travel. Typical constraints include a maximum of two packs per passenger, mandatory declaration, and prohibition of spare packs in the aircraft hold–most carriers allow carriage only in the cabin with approval.
- >160 Wh: Prohibited on passenger aircraft both in cabin and hold. Transport only as regulated dangerous goods via cargo/freighter service with operator acceptance, special packaging, labeling and dangerous‑goods paperwork (classification under UN3480/UN3090 for lithium cells/packs).
How to confirm Wh and quick calculations
Formula: Wh = (mAh ÷ 1000) × V. Use the cell nominal voltage (commonly 3.6–3.7 V), not the USB output voltage. Examples: 10,000 mAh at 3.7 V = 37 Wh; 20,000 mAh at 3.7 V = 74 Wh; 30,000 mAh at 3.7 V = 111 Wh (exceeds 100 Wh threshold).
- Prefer the manufacturer’s Wh marking if present; if only mAh is listed, compute Wh using the cell voltage.
- If calculated Wh falls into the 100–160 Wh band, obtain written approval from the carrier before travel and carry proof of approval.
- For packs over 160 Wh, arrange cargo/freighter shipping with a carrier that accepts lithium consignments–do not attempt passenger carriage.
- Pack terminals to prevent short circuits and retain original labeling or documentation showing the Wh rating for inspection.
Converting mAh to Wh: quick method to verify your power bank’s classification
Recommendation: Use Wh = (mAh ÷ 1000) × V and assume nominal cell voltage 3.7 V when only mAh is printed; if the computed Wh is under 100 Wh the unit normally fits standard cabin limits, 100–160 Wh usually requires carrier approval, above 160 Wh is prohibited from air transport.
Step-by-step: Read the mAh on the label. If Wh is printed, use that value. If only mAh is shown, convert: Wh = (mAh/1000) × V. If the label omits voltage, use 3.7 V for typical Li-ion cells; use 3.85 V for a conservative estimate.
Examples: 5,000 mAh → (5,000/1000)×3.7 = 18.5 Wh. 10,000 mAh → 37 Wh. 20,000 mAh → 74 Wh. 26,800 mAh → 99.16 Wh. 50,000 mAh → 185 Wh (exceeds 160 Wh threshold).
When output voltage is shown (e.g., 5 V): Do not use the USB output voltage for internal energy calculation. If only output mAh is listed, look for a Wh label or consult manufacturer specifications; converting output-rated mAh to cell Wh requires the device’s energy conversion efficiency and is unreliable without manufacturer data.
Quick verification checklist: use printed Wh if present → if not, convert mAh with 3.7 V → round up for safety (use 3.85 V if unsure) → compare with 100 Wh and 160 Wh thresholds. For a compact travel scale option see best luggage scale australia.
Packing steps if hold carriage is allowed: insulating terminals, power-off, and labeling
Tape exposed terminals with high-quality non-conductive tape (electrical or Kapton), covering each terminal twice and trimming excess tape so no conductive metal is exposed.
Place each power bank in its own resealable plastic bag or original retail box; add foam or bubble wrap and store inside a rigid case or between soft garments to prevent crush damage and contact with metal objects.
Power the unit off and disable auto‑on or pass‑through charging features; remove all cables and accessories. Recommended state of charge for storage: ~30–50% for extended trips. Confirm the unit remains inert by briefly pressing the power button after taping–no LEDs or startup sequence should occur.
Affix a clear label showing rated Wh and mAh. If only mAh is listed, calculate Wh = (mAh × nominal voltage) / 1000; use 3.7 V for single‑cell Li‑ion packs. Example: 20,000 mAh → 20,000 × 3.7 / 1000 = 74 Wh. For units >100 Wh, include written airline approval and the manufacturer specification sheet in an external pocket of the bag presented at check‑in.
Do not place multiple units together unprotected; separate with padding and avoid pockets with loose coins, keys, or tools. Keep documentation visible for inspection and follow carrier instructions at the time of surrender to the aircraft hold.
How to check your airline and country rules before you fly
Check the carrier’s hazardous-goods and restricted-items pages plus departure and destination civil aviation authority notices at least 72 hours before departure.
Practical verification steps: search the airline site for “dangerous goods”, “restricted articles”, “special baggage” and the product model number; if web guidance is ambiguous, contact the airline hazardous‑goods or cargo office by phone and request email confirmation; check the national aviation authority and customs pages for both origin and destination states; consult the departure and arrival airport security advisories; retain the manufacturer’s specification sheet and purchase receipt to present to staff.
When contacting authorities or the airline, request explicit written approval for transport conditions and any declaration forms required at the ticket counter. For transit through third countries, verify rules for intermediate airports as some jurisdictions apply different controls. If documentation is not provided, declare the item at check‑in and expect on‑the‑spot adjudication by the carrier.
| Source | Exact pages / search terms | How to contact | Recommended lead time |
|---|---|---|---|
| Airline website | “dangerous goods”, “restricted articles”, “special baggage”, product model number | Customer service phone; hazardous‑goods or cargo office email; web chat if available | 72 hours; earlier at booking if uncertainty exists |
| Airline special approvals | Policy pages on special approvals or exceptions, downloadable forms | Formal email request with product specs; retain written reply | 7–14 days when formal approval likely required |
| Departure civil aviation authority | “transport of dangerous goods”, “restricted articles” guidance | Official website, regulatory hotline, email | 72 hours |
| Destination civil aviation authority & customs | Import restrictions, permitted items, declaration requirements | Customs website, embassy/consulate if language or legal clarity needed | 72 hours; earlier for commercial quantities |
| Airport security | Screening advisories and local facility rules | Airport information desk, security operations email | 48–72 hours |
| Ground handling agent / travel agent | Handling procedures, on‑site declaration process | Agent phone or booking agent email | 48–72 hours |
If written confirmation is issued, carry printed copies and the original product label; if rules remain unclear or no permission is received, passengers should avoid transporting the item rather than risk refusal, confiscation, or travel delay.
Penalties and inspection outcomes when a power bank is found in hold baggage
Declare any power bank discovered in the aircraft hold to security personnel immediately; expect the item to be removed for safety screening, possible seizure, and administrative penalties depending on local rules.
Likely inspection sequence
Screening will normally flag the item on X‑ray, then a manual search of the bag will follow. Inspectors will identify cell chemistry and watt‑hour rating from labels or by measurement, photograph the item, and either: 1) permit removal and return to the passenger at the gate if regulations allow transfer to cabin baggage, 2) seize and retain the unit for disposal if prohibited, or 3) isolate the entire bag and involve fire/HAZMAT teams if there is evidence of damage, leakage or thermal runaway. Flight dispatch may offload the bag; that can delay or cancel carriage of the entire aircraft if a safety risk is assessed.
Possible sanctions and remediation steps
Outcomes range from receipt‑level confiscation with no fine to formal civil penalties, airline refusal of carriage, and criminal referral for deliberate concealment. Typical administrative measures include written seizure receipts, incident reference numbers, and temporary travel bans by the carrier. Monetary penalties often start in the low hundreds at many airports and can escalate into thousands where intentional rule breaches or hazardous conditions are proven.
Recommended actions after discovery: present original packaging or manufacturer label showing Wh rating and model; request a written seizure/inspection report and incident reference; photograph the item and bag condition; ask whether the item will be returned, destroyed, or mailed and obtain timelines and contact details; file a formal query with the carrier and the local aviation authority if needed. Retain all documentation for insurance or appeals.
FAQ:
Can I pack a portable power bank in my checked luggage?
No. Most airlines and aviation authorities require spare lithium batteries, including portable phone chargers (power banks), to travel in carry-on baggage only because they can pose a fire risk if damaged or shorted. General limits applied by carriers and regulators: batteries up to 100 Wh are normally allowed in the cabin without approval; batteries between 100 Wh and 160 Wh require airline approval and are typically limited to two per passenger; batteries above 160 Wh are usually prohibited on passenger aircraft. To estimate watt-hours, use Wh = (mAh × V) / 1000 (many power banks use about 3.7 V). Example conversions: 10,000 mAh ≈ 37 Wh, 20,000 mAh ≈ 74 Wh, 30,000 mAh ≈ 111 Wh (which would likely need airline approval). Pack power banks in your carry-on, protect terminals (original packaging, tape over terminals, or insulating sleeves), and keep them accessible for inspection.
