Michael Turner
Immediate rule: Spare rechargeable cells and external power packs belong in the passenger cabin only. Uninstalled cells are prohibited from the aircraft hold. Devices with internal cells (laptops, cameras, phones) may be transported in hold at some carriers’ discretion, but cabin carriage is strongly recommended for rapid detection and response.
Capacity limits: Cells rated up to 100 Wh are permitted in carry-on without airline approval. Cells between 100 Wh and 160 Wh require airline approval and are limited to a maximum of two spare units per passenger, carried in the cabin. Cells over 160 Wh are not allowed on passenger aircraft under standard rules (seek cargo procedures for freight transport).
How to verify ratings: Look for a watt‑hour (Wh) label on the cell or pack. If only milliamp‑hours (mAh) and voltage (V) are shown, calculate Wh = (mAh × V) / 1000. Example: a 20,000 mAh power bank at 3.7 V = (20,000 × 3.7) / 1000 = 74 Wh. Typical smartphone packs are ~10–15 Wh; most laptop packs range ~30–100 Wh.
Packing steps for cabin carriage: 1) Keep spare cells and power banks in carry-on; 2) Protect terminals with original caps, electrical tape, or individual plastic pouches to prevent short circuits; 3) Place each spare in its own compartment or original packaging; 4) Power off devices and enable any protective measures (switch lock, set to airplane mode if required); 5) Declare packs above 100 Wh to the airline and obtain written approval if needed.
Operational tips: Check the airline’s website before travel–some carriers impose stricter limits than regulatory bodies (FAA/IATA/ICAO). For checked hold carriage of equipment with built‑in cells, verify whether the carrier accepts such items and follow any packaging or protection instructions. When traveling internationally, confirm both departure and arrival country restrictions and customs rules for high‑capacity packs.
In case of damage or fault: Do not place swollen, leaking, or damaged cells in baggage of any type. Isolate the damaged unit in a non‑flammable container and contact airline ground staff for instructions; damaged cells are typically refused for transport.
Which chemistries and cell types are allowed in the aircraft hold?
Recommendation: only primary Li‑metal cells installed inside equipment and rechargeable Li‑ion packs with a marked energy ≤100 Wh may be carried in the aircraft hold; spare cells and spare packs must be transported in the cabin (carry‑on) rather than stored in the hold.
Rechargeable (Li‑ion) – examples: LiCoO2, NMC, NCA, LiFePO4. Rules: packs or cells with a nameplate Watt‑hour rating ≤100 Wh are permitted when installed in devices in either cabin or hold; spare packs are prohibited in the hold. Packs >100 Wh and ≤160 Wh require airline approval and, if allowed, are limited (typically up to two spare packs) and must remain in the cabin. Packs >160 Wh are not accepted on passenger aircraft except as cargo with special permits. Verify Wh on the label; convert from mAh using Wh = (mAh/1000) × V.
Primary (Li‑metal) – used in some cameras and specialty devices. Rules: cells with lithium content ≤2 g per cell are permitted when installed in equipment in cabin or hold; spare primary cells are not permitted in the hold and must be carried in the cabin. Cells with >2 g lithium require operator approval and are generally restricted on passenger flights.
Integrated packs and large equipment – if a device has a manufacturer’s Wh marking, follow that rating. Devices with non‑removable packs should have power switches off and terminals protected. High‑capacity equipment (e‑bikes, power tools, large power banks) frequently exceeds allowable limits for passenger aircraft and is commonly refused in the hold; consult the carrier for approval before transport.
Watt-hour (Wh) limits and when cells/packs must remain in carry-on
Keep spare Li‑ion cells and packs in the cabin carry-on; spares are forbidden in the aircraft hold.
0–100 Wh: Packs/cells installed in equipment may travel in either cabin or aircraft hold. Spare packs/cells under 100 Wh must be carried in the cabin and protected from short circuits.
>100–160 Wh: Packs/cells greater than 100 Wh and up to 160 Wh are allowed only in the cabin and normally require airline approval; maximum two spare packs per passenger. Devices containing packs in this range commonly require airline approval for transport and are often barred from the aircraft hold without explicit carrier permission.
>160 Wh: Packs/cells above 160 Wh are not permitted on passenger aircraft in cabin or aircraft hold except under special cargo acceptance with dangerous-goods handling; do not attempt regular passenger carriage.
Handling checklist: label Wh rating on each pack; leave packs installed in devices when feasible; protect terminals (tape or terminal covers); carry original packaging if available; limit the number of spare packs to what is necessary for the trip; power off devices during transport.
| Wh rating | Spare packs/cells | Installed in device | Airline approval |
|---|---|---|---|
| ≤100 Wh | Allowed in cabin only | Allowed in cabin or aircraft hold | Not required (standard limits) |
| >100–160 Wh | Allowed in cabin; max 2 spares; airline approval usually required | Often allowed with airline approval; aircraft hold frequently restricted | Required |
| >160 Wh | Prohibited on passenger aircraft (cargo only with special DG procedures) | Prohibited on passenger aircraft (cargo only with special DG procedures) | Not permitted under normal passenger carriage |
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Spare cells and packs: rules for placement in the aircraft hold
Do not store spare cells or power packs in the aircraft hold; carry them in cabin baggage unless explicit, written approval from the carrier or state aviation authority allows otherwise.
Packing steps for spare cells/packs
Insulate terminals with non-conductive tape or use terminal covers; place each cell or pack in its original retail packaging or an individual plastic pouch to prevent contact between terminals.
Store spare items inside a rigid case or a dedicated compartment within cabin carry-on to limit movement and physical damage during transit.
For portable chargers and high-capacity packs, keep them switched off and ensure any built-in indicators cannot activate accidentally during flight.
Airline and regulator actions
Most major carriers and IATA/ICAO rules require spares to remain in cabin; carriers may refuse carriage, remove items at screening, or impose fines if regulation is breached.
Declare unusually large quantities or non-standard pack types to the carrier in advance; written airline approval is typically required for packs above the carrier’s standard allowance.
Do not attempt to transport damaged, swollen, or recalled cells or packs in cabin or hold; such items are generally forbidden and will be confiscated for safety reasons.
How to pack devices with installed cells to prevent short circuits and damage
Power devices off completely and isolate terminals before stowage. Disable wake-on features and remove external cables, SIM trays or memory cards that could shift and trigger operation.
Seal exposed contacts and ports with non-conductive tape (Kapton or standard electrical tape) or use manufacturer-supplied rubber caps. For contact strips apply a 2–3 cm-wide strip across the full contact area and press edges to avoid peeling.
Use dedicated protective solutions: rigid shell cases for laptops/tablets; padded sleeves or neoprene pouches for phones and cameras; small devices in individual zippered pouches to prevent rubbing or contact. Place larger electronics inside a best backpack for grad school-style padded compartment when available.
Cushion each item with at least two layers of padding (foam, folded garments or bubble wrap). Position devices away from exterior walls and zippers–center placement reduces risk of impact and compression from surrounding contents.
Avoid proximity to loose metal objects (keys, coins, pens). Store accessories and charging cables in sealed plastic bags or separate pockets to eliminate accidental terminal bridging.
Prevent accidental activation by covering power buttons with tape or using cases that block switches. For slide or push buttons, apply tape across the button and adjacent surface to keep it immobile.
Protect against crushing by using hard-sided cases or by inserting rigid dividers between heavy items. For fragile internal assemblies, add thin foam plates on both faces of the device to distribute pressure.
Keep devices away from sharp or pointed items (umbrella frames, tools); for small folding umbrellas consider dedicated storage rather than loose placement – example product reference: best mini umbrella blunt.
If carrier policies require declaration for high-capacity power cells, carry manufacturer documentation and present at check-in. For transit safety, ensure devices are fully powered down and packaged according to the device maker’s transport guidance.
How to declare high-capacity power packs and obtain airline approval
Declare high-capacity power packs to the carrier at least 48 hours before departure and secure written approval; transport will be refused without explicit authorization.
Immediate data to provide
- Watt-hour rating per pack (Wh). Calculate as: nominal voltage × ampere-hours (V × Ah).
- Number of packs and whether installed inside a device or spare, with serial numbers if available.
- Chemistry type (e.g., Li‑ion, Li‑polymer) and manufacturer model number.
- State of charge (SOC) percentage for packs >100 Wh; carriers commonly require ≤30% SOC.
- Origin, destination, flight number and date, and intended transport mode (passenger cabin vs. cargo).
Step-by-step approval process
- Calculate Wh for each pack and prepare manufacturer specification sheet or label photograph.
- Contact the airline’s Dangerous Goods Regulations (DGR) or special cargo desk by phone or email; reference the specific flight. Use the carrier’s published DGR contact if available.
- Submit required details (those listed above) and request written confirmation (email or form). Verbal permission is insufficient at check-in.
- Follow any carrier-imposed limits: most accept packs 100–160 Wh only with prior approval and typically limit number per passenger; packs >160 Wh are usually prohibited from the passenger cabin and may require special cargo acceptance under DG procedures.
- If accepted as cargo, arrange shipment with a DG-certified freight forwarder and provide a completed Shipper’s Declaration for Dangerous Goods and applicable packaging/marking per IATA/ICAO.
- Bring printed approval to check-in and present packs in required packaging; expect inspection at the security or check-in counter.
Packaging and marking instructions from the carrier must be followed exactly: terminals insulated, each pack individually protected, original or equivalent rigid outer packaging, and clear labeling if transported as dangerous goods. Retain all correspondence with the airline during travel and for the return trip.
