Michael Turner
Spanish airports apply IATA and EU rules: spare lithium-ion cells and portable power banks are permitted only in hand/cabin baggage, not in checked baggage. Cells with a rating under 100 Wh per cell are allowed without airline approval. Cells between 100 Wh and 160 Wh require prior airline approval and are limited to a maximum of two spare cells per passenger. Cells above 160 Wh are forbidden on passenger aircraft.
Devices with internal power cells (installed in equipment) may be transported in either cabin or checked baggage, but terminals must be protected and devices switched off. Portable power banks are treated as spare lithium-ion cells: they must remain in hand baggage and follow the same Wh limits. Airlines and airport operators in Spain frequently refuse acceptance of spare power sources placed in checked baggage at check-in.
Non-rechargeable lithium metal cells are allowed in hand baggage only when lithium content is ≤ 2 g per cell; cells exceeding that threshold are prohibited on passenger flights. Common consumer chemistries such as alkaline or NiMH (AA/AAA/AAA) are permitted in both hand and checked baggage with no special Wh paperwork, though excessive quantities may trigger airline interrogation.
Practical packing steps: insulate terminals with tape or original covers, keep spare cells in original retail packaging or individual plastic pouches to prevent short circuits, label power banks with Wh or voltage/Ah so staff can verify compliance, and disclose any cells rated >100 Wh to the airline before travel. Check the specific carrier’s policy and Aena guidance for Spanish airports before departure to avoid refusal at the gate.
Rules for transporting power cells in cabin baggage at Spanish airports
Place spare lithium-ion cells and portable power packs only in cabin baggage; spare units are prohibited in checked baggage. Cells installed inside equipment may be stowed in the hold if terminals are protected, but cabin storage is preferred and safer.
Limits, markings and examples
Watt-hour thresholds: <100 Wh allowed without airline approval; 100–160 Wh permitted only with airline approval (maximum two spare cells/packs per passenger); >160 Wh forbidden on passenger aircraft. For lithium metal cells the limit is 2 g lithium content; above 2 g not permitted. Convert mAh to Wh via Wh = (mAh/1000) × V (typical cell voltage 3.7 V). Examples: smartphone cell ~5–15 Wh; laptop pack ~40–90 Wh; a 20,000 mAh power bank ≈ 74 Wh.
Packing and documentation recommendations
Insulate terminals (tape over contacts or keep in original retail packaging) and protect against short circuits and damage. Keep portable chargers and spare cells accessible in cabin screening. Carry model/Wh labels or manufacturer specs for any unit near the 100–160 Wh band and request airline approval in advance. Follow AESA, EASA and IATA guidance and check individual carrier rules before departure; security staff at Spanish airports will enforce these limits and may require declaration of oversized units.
Permitted alkaline, NiMH and lithium cell rules for Spanish cabin
Pack alkaline and NiMH cells in either checked baggage or hand baggage; treat spare lithium-ion and lithium-metal cells as hand-baggage only, with terminals insulated and capacity/content limits respected.
Specific allowances and limits
- Alkaline (single‑use): Standard AA/AAA/C/D/9V cells are permitted in both checked and hand baggage. Store in original packaging or in plastic cases to prevent short circuits.
- NiMH (rechargeable): Permitted in checked and hand baggage. Prefer keeping spares inside device or in protective cases; no watt‑hour marking required.
- Lithium‑ion (rechargeable, e.g., phone/tablet/power bank cells): Spare units and power banks must remain in hand baggage. Individual cell/battery rating rules:
- ≤100 Wh: allowed without airline approval.
- >100 Wh and ≤160 Wh: allowed only with airline approval; typically limited to two units per passenger.
- >160 Wh: prohibited in passenger aircraft.
- Lithium‑metal (non‑rechargeable, e.g., some button cells): Installed in equipment generally allowed. Spare lithium‑metal cells permitted in hand baggage only if lithium content ≤2 g per cell; cells with higher lithium content are not permitted on passenger aircraft.
Packing and practical recommendations
- Insulate terminals on all spare cells using original packaging, terminal covers, or non-conductive tape; place each cell in individual plastic cases or resealable bags.
- Labelled watt‑hour (Wh) marking is required for lithium‑ion units; airlines may ask to verify rating for power banks.
- Limit the number of spare high‑capacity lithium devices; check the carrier’s policy before travel (airlines often have stricter limits than regulators).
- Do not place loose cells in pockets or with metal objects (keys, coins).
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Watt-hour and lithium cell limits for cabin baggage on flights departing from Spanish airports
Keep all spare lithium cells and portable chargers in cabin baggage; spare cells and power packs are prohibited in checked baggage.
Watt‑hour thresholds (rechargeable lithium‑ion)
Up to 100 Wh: permitted in cabin without airline approval for both installed and spare cells/packs. 100–160 Wh: allowed only with airline approval and normally limited to two spare units per passenger. Above 160 Wh: forbidden on passenger aircraft (transport only as cargo under special provisions).
Power pack labeling: Wh rating must be printed on the unit. If only mAh and voltage are shown, calculate Wh = V × Ah (Ah = mAh ÷ 1000). Example: 3.7 V × 2000 mAh = 3.7 × 2 = 7.4 Wh.
Lithium‑metal (primary) cell limits and handling
Individual lithium‑metal cells with lithium content ≤2 g per cell are permitted in cabin only; cells with greater lithium content require airline approval and are usually forbidden for passenger transport. All spare cells and packs must have terminals insulated (tape, terminal caps, or original packaging), be protected from short circuits, and be carried in a way that prevents activation or damage.
Final recommendation: check the operator’s policy before travel for any device or pack rated between 100–160 Wh, keep spares limited and protected, and ensure all items are clearly marked with Wh or voltage/mAh for quick inspection.
How to pack spare lithium cells in cabin baggage to comply with Spanish and EU rules
Keep all spare lithium cells and power packs in cabin baggage; never place them in checked baggage.
Inspect each cell or pack for dents, swelling, leaks or corrosion before packing; damaged units must not be transported. Protect terminals by covering exposed contacts with non-conductive tape or by leaving them in original retail packaging. Place each item inside an individual plastic pouch, zip bag or manufacturer-supplied sleeve to prevent contact between terminals and other metal objects.
Use padding to prevent crushing: rigid containers, foam inserts or individual compartments in a pouch reduce movement and impact. Do not pack spare cells loose in pockets, loose compartments with tools, or next to sharp objects. Store power banks separately from devices and avoid stacking multiple packs without separators.
Label high-capacity packs when possible (Wh rating). Convert mAh to Wh using Wh = (mAh × V)/1000; example: a 27,000 mAh pack at 3.7 V ≈ 100 Wh. Packs above 100 Wh require airline approval and additional restrictions under EU/IATA rules, so verify carrier policy before travel. Do not declare lower-risk installed cells unnecessarily; keep spares accessible for inspection by security staff.
Avoid improvised terminal protection (exposed foil or loose tape). Prefer original packaging or purpose-made battery sleeves. Keep the total number of spare packs reasonable and use only manufacturer-approved replacements. If transporting household tools or appliances alongside cells, separate power sources into different compartments and consult specific carrier guidance.
Power banks and external chargers are treated as spare lithium-ion items and must remain in cabin baggage. If uncertain about a specific item or its rating, check the airline and the Spanish aviation authority guidance before departure and follow crew instructions at the airport. For unrelated household moving tips that may help when packing heavy items, see best gliders for a washing machine.
Airline and airport checks: who to contact and what documentation to present
Contact the operating carrier’s dangerous-goods desk and the departing airport’s security office before travel; present manufacturer specification sheets showing Wh (or mAh and voltage), written airline authorization for items above 100 Wh, and photos or original packaging proving quantity and protection of terminals.
Primary contacts
Start with the carrier that issues the boarding pass – its Dangerous Goods (DG) or Special Assistance team handles approvals and written confirmations. If uncertain at the airport, approach the main security control point or the airport operations office (often listed under “operations” or “security” on the airport website). For regulatory interpretation, contact the national aviation authority and the airport operator.
| Entity | Who to reach | What to present |
|---|---|---|
| Operating carrier (DG desk) | DG/Special Cargo or Customer Service (phone/email listed on carrier site) | Written request or pre-approval email; manufacturer spec sheet with Wh or mAh+V; quantity and configuration details |
| Departure airport security office | Security supervisor / Operations desk (info on airport website) | Original product packaging or clear photos, taped terminals for loose cells, printed manufacturer specs |
| Airport operator (AENA or equivalent) | Passenger information desk / legal office | Carrier approval copy, product technical sheet, proof of declared capacity |
| National aviation authority (AESA or equivalent) | Regulatory enquiries / Dangerous Goods office | Reference to applicable EU/IATA regulation, technical datasheet, formal complaint or clarification request |
Documentation checklist to have ready at screening
– Manufacturer technical datasheet or Safety Data Sheet (SDS) showing Wh or mAh and voltage; if only mAh provided, include voltage to calculate Wh (Wh = mAh × V / 1000).
– Written airline approval for items exceeding 100 Wh (email printout or airline form).
– Original packaging or clear photos of product labels; spare cells must have terminals taped or be in protective sleeves.
– Quantity list and itemized declaration if carrying multiple power sources; include serial numbers when available.
– If transporting professionally packed or bulk shipments, provide the carrier’s DG declaration form and any transport document required by IATA/ICAO.
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Rules for power-pack mobility aids and how to obtain airline approval in Spanish airports
Obtain written airline approval at least 72 hours before departure by submitting full device and power-pack specifications plus UN 38.3 documentation; present that approval at special assistance and check-in counters.
Information to submit: passenger name, flight number and date, device make/model and serial number, power-pack chemistry (Li‑ion, Li‑metal, NiMH, sealed lead‑acid), capacity expressed in Wh or lithium content in grams, number of cells/modules, whether the power-pack is installed or removable, whether spare power-packs are included, photos of label/markings and of the device, MSDS and UN 38.3 test certificate or manufacturer declaration.
Timing and format: send the full dossier by email to the carrier’s special assistance or dangerous-goods acceptance address; request a written approval or special handling reference code. Many operators require a 72-hour minimum; some require up to 7 days. No verbal approval acceptable without written confirmation.
At the airport: present printed approval and device documentation to special assistance staff at arrival and at check-in. Ensure the power switch is disabled, controls are protected against accidental activation, wheels are immobilised if required, and terminals are insulated (taped or terminal caps). Removable power-packs must be removed when the carrier’s procedure specifies removal; spares and removed packs must be protected against short circuit and kept with the passenger in the cabin or handed to staff per the approval.
Packaging and marking expectations: terminals insulated, power-pack secured against movement inside the device, exposed metal covered, and the device labelled with the power-pack type and capacity. Some carriers require the device to be accompanied by the manufacturer’s instructions for disconnection and safe handling.
Special chemistries: sealed lead‑acid units often require electrolyte leakage protection and may be accepted only with operator approval and specific cushioning; flooded or non‑sealed lead cells are generally refused. Li‑metal packs require UN 38.3 evidence and usually tighter restrictions; expect stricter screening and a higher likelihood of denial without complete paperwork.
Interaction with regulators and appeals: the carrier issues approval or denial. For unresolved refusals, file a complaint with the Spanish Aviation Authority (AESA) at the addresses on aesa.gob.es and lodge an airport complaint with the relevant airport operator (Aena). Include the carrier’s written decision and the submitted technical dossier when appealing.
Practical checklist before travel: obtain written approval reference; carry printed UN 38.3 or manufacturer statement; photos of labels; tape or terminal covers; toolset for disconnecting if the approval requires removal; plan arrival time to allow extra handling (arrive significantly earlier than standard check-in times); request confirmation of where the device will be stowed during flight and how gate handling will be performed.
Airlines retain final authority; production of complete technical documentation and prior written acceptance markedly increases likelihood of acceptance and smooth handling at Spanish airports.
