Michael Turner
Immediate rule: spare lithium‑ion and lithium‑metal power packs (including portable chargers and external packs) are allowed only in carry‑on; loose spare cells are forbidden in the aircraft hold under ICAO/IATA and TSA/FAA guidance. Cells installed inside equipment may sometimes be placed in the hold, but operators commonly require devices to be powered off and protected against accidental activation.
Numeric limits: lithium‑ion: up to 100 Wh per cell/pack permitted in cabin without airline approval; packs between 100 Wh and 160 Wh require airline approval and are generally limited to two spare packs per passenger; packs > 160 Wh are prohibited on passenger aircraft. Lithium‑metal cells: lithium content ≤ 2 g per cell allowed in cabin; > 2 g is forbidden on passenger aircraft.
How to calculate Wh: Wh = voltage (V) × capacity (Ah) = V × (mAh/1000). Examples: a typical smartphone cell ≈ 10–15 Wh; a laptop main pack ≈ 40–90 Wh; a 20,000 mAh portable charger at 3.7 V ≈ 74 Wh. If Wh is not printed, calculate and present the figure when requested by an airline or security agent.
Packing checklist: keep all spare cells/packs in cabin; insulate terminals (original retail packaging, taped terminals, or individual plastic sleeves); store spare packs inside a protective pouch; do not place spare packs in checked/hold baggage; request airline approval before traveling with packs 100–160 Wh and carry documentation or product spec sheet; declare oversized cells when asked by carrier or security personnel.
Transport rules for lithium power cells in the aircraft hold
Do not stow spare lithium‑ion or lithium‑metal power packs in the aircraft hold; carry all spares inside the passenger cabin only.
Regulatory limits: rechargeable lithium‑ion cells up to 100 Wh are permitted as spares in cabin; cells between 100 Wh and 160 Wh require airline approval and are limited (typically two spares per passenger) and must remain in cabin; cells above 160 Wh are forbidden on passenger aircraft. Non‑rechargeable lithium‑metal cells containing more than 2 g of elemental lithium are prohibited on passenger aircraft; cells with ≤2 g are carried in cabin under airline and national rules.
Installed power sources inside devices: devices with factory‑installed packs may be transported in the hold by some carriers if terminals are protected and devices are powered off, but many airlines prefer these devices in cabin. Certain items (power banks, portable chargers, e‑cigarettes/vaping devices) are universally classified as spares and must be kept in the cabin; e‑cigarettes are not permitted in the hold.
Packing recommendations: isolate terminals with tape or original packaging, place each spare in individual protective sleeves or original retail boxes, shield against short circuits, and switch devices off completely to prevent accidental activation. For packs >100 Wh, attach or retain a manufacturer watt‑hour label and obtain explicit airline approval before travel.
Before travel, verify carrier‑specific and departure/arrival country regulations (IATA/ICAO/FAA guidance applies as baseline). Declare any items requiring approval at check‑in and accept any carrier restrictions or refusals.
Which cell chemistries are prohibited in the aircraft hold?
Do not stow spare lithium‑metal (primary) or lithium‑ion (rechargeable) cells in the aircraft hold; spares must be transported in cabin baggage and are subject to watt‑hour and lithium‑content limits.
Lithium‑ion: cells above 100 Wh require airline approval; cells above 160 Wh are forbidden on passenger flights. Lithium‑metal: cells containing more than 2 g of lithium are forbidden on passenger flights. Damaged, defective, or recalled cells of any chemistry are banned from both cabin and hold and require special handling.
Large lead‑acid (wet/flooded) and industrial power cells are generally not permitted in passenger hold and must move as cargo under dangerous‑goods procedures. Common consumer chemistries (alkaline, NiMH, NiCd, silver‑oxide, zinc‑air) are typically allowed when installed in equipment; loose spares require terminal protection and adherence to airline quantity limits.
| Chemistry | Permitted in aircraft hold? | Notes / limits |
|---|---|---|
| Lithium‑ion (Li‑ion, Li‑poly) | Spare units: prohibited; installed in equipment: may be allowed | >100 Wh: airline approval required; >160 Wh: prohibited on passenger flights; terminals insulated and device powered off when installed |
| Lithium‑metal (primary) | Spare units: prohibited; installed in equipment: limited exceptions | Lithium content >2 g: forbidden on passenger flights; spares must remain in cabin |
| Damaged / recalled cells (any chemistry) | Prohibited | Must not travel in cabin or hold; arrange specialised transport |
| Lead‑acid (wet / flooded) | Generally prohibited in passenger hold | Transport only as cargo under dangerous‑goods rules; sealed/maintenance‑free types may have conditional allowances |
| Alkaline, NiMH, NiCd, silver‑oxide, zinc‑air | Allowed when installed; spares allowed with precautions | Protect terminals against short circuits; observe airline quantity and packaging rules |
Watt‑hour (Wh) and cell limits for cabin and aircraft hold energy packs
Keep all spare lithium‑ion power packs in the cabin; do not stow spares in the aircraft hold.
Wh thresholds and passenger rules
• ≤100 Wh: permitted without airline approval as installed in devices and as spare units carried in the cabin. Typical examples: smartphones ~10–15 Wh, tablets ~20–40 Wh, many laptops 30–100 Wh, power banks 20,000 mAh (3.7 V) ≈74 Wh. Airlines may still set practical quantity limits for personal use.
• >100 Wh and ≤160 Wh: transport requires airline approval. Spare packs in this band are limited to a maximum of two per passenger and must remain in the cabin with terminals protected. Devices containing units in this band generally require declaration and airline permission at check‑in.
• >160 Wh: not permitted on passenger aircraft in either cabin or aircraft hold. Movement only under cargo dangerous‑goods procedures with carrier approval and appropriate packaging/labels.
Cell limits, marking and handling
• Lithium‑metal cells with lithium content exceeding 2 g are forbidden on passenger flights in both cabin and aircraft hold; cells with ≤2 g are generally acceptable when installed in equipment. Spare lithium‑metal cells must be carried only in the cabin and individually protected against short circuits.
• Wh calculation: Wh = V × Ah. Convert mAh to Ah by dividing by 1000 (example: 3.7 V × 2800 mAh = 3.7 × 2.8 = 10.36 Wh). If Wh is not printed, calculate and label the pack before travel.
• Terminal protection and packaging: insulate terminals with tape or use original retail packaging; place each spare in individual protective sleeves or plastic bags to prevent contact. Carry documentation or proof of Wh rating when possible.
• Airline coordination: always check carrier rules before travel for limits on the number of spare packs ≤100 Wh, approval process for 100–160 Wh units, and any declaration procedures at check‑in. Failure to obtain required approval may result in denied transport or removal of the item from the aircraft.
How to pack and insulate spare lithium‑ion and lithium‑metal cells for aircraft hold
Insulate all terminals, place each cell in its own non-conductive sleeve or original packaging, restrict state‑of‑charge to about 20–30% for lithium‑ion packs, and enclose groups inside a rigid, fire‑resistant container that prevents movement and separates cells from flammable materials.
- Required materials
- Non‑conductive terminal caps or high‑adhesion electrical tape (cover all exposed metal).
- Individual plastic sleeves or original molded trays.
- Zip‑seal plastic bags for moisture/barrier protection.
- Closed‑cell foam, cardboard dividers or molded inserts to prevent contact and absorb shock.
- Rigid outer box or hard case; optional certified fire‑resistant pouch/box for added protection.
- Packing sequence
- Inspect each cell: discard if swollen, damaged, leaking or showing discoloration.
- Cover every terminal completely with caps or tape; extend tape beyond terminal edges to avoid exposure if tape shifts.
- Place each cell into its own sleeve or the original insulated tray; do not allow cells to touch one another.
- Enclose sleeved cells inside zip‑seal bags in small groups (1–4 cells per bag depending on size), expel excess air, and seal tightly.
- Use foam inserts or cardboard separators inside a rigid box so cells cannot shift, collide or experience crushing forces.
- Surround the inner pack with at least 2–3 cm of cushioning on every side; secure the inner pack to the outer case to prevent movement.
- Place the sealed inner pack inside a certified fire‑resistant pouch or metal container if available; otherwise use a heavy‑gauge hard case and mark contents for emergency responders if required by carrier policy.
- Segregation and labeling
- Keep lithium‑ion (rechargeable) cells separate from lithium‑metal (primary) cells; do not mix chemistries in the same inner bag or compartment.
- Do not pack loose metal objects, spare fuel, or combustible items adjacent to cell packages.
- If carrier or dangerous‑goods rules require, affix appropriate handling labels and documentation to the outer case.
- Storage and handling notes
- Maintain state‑of‑charge for lithium‑ion modules around 20–30% for transport longevity and reduced thermal risk.
- Keep cell temperature stable prior to travel; avoid leaving packs in hot vehicles or direct sunlight.
- Do not attempt to repair, rewrap or recharge compromised cells; hand over to an approved recycling or hazardous‑waste handler.
- Emergency mitigation
- Use metal or fire‑resistant containment if suspecting damage during transit; small thermal events can be contained by specialized pouches designed for lithium incidents.
- If an outer case shows signs of smoke, heat or leakage on arrival, isolate the case in a well‑ventilated, non‑occupied area and notify ground handling staff immediately.
Rules for devices with non‑removable power cells in hold baggage
Recommendation: Store devices with non‑removable lithium‑ion cells in cabin baggage whenever possible; if the cell rating is ≤100 Wh the device may be transported in the aircraft hold when switched off and protected; cells rated 100–160 Wh require airline approval and are restricted to the cabin; cells >160 Wh are prohibited on passenger flights.
Specific limits: Installed rechargeable lithium‑ion cells – ≤100 Wh: permitted in both cabin and hold; 100–160 Wh: permitted only in cabin with carrier approval; >160 Wh: forbidden. Installed non‑rechargeable lithium‑metal cells – ≤2 g lithium content per cell: generally permitted when installed in equipment; >2 g: forbidden on passenger aircraft. Individual carrier policies may be stricter; follow the carrier’s written requirements.
Packing and protection requirements for devices with non‑removable cells: power the device fully off (not standby), physically block any power switch or lens/trigger mechanisms that could activate, place in a hard protective case or wrap with cushioning to prevent crushing, ensure contacts cannot short (built‑in terminals should be recessed or covered), and avoid placing heavy items on top. Do not rely on soft clothing alone for protection.
Documentation and approval: retain manufacturer documentation showing watt‑hour rating or lithium content and present it at the check‑in counter or to the carrier’s hazardous‑goods desk when requested. Obtain written airline approval for devices rated 100–160 Wh before the travel date. Flight crew and ground staff have final authority to refuse carriage.
Note: Many compact optics and imaging devices include integrated power cells; see best digital camera binoculars for photography for examples and verify the power specifications before travel.
If a loose lithium‑ion cell is found in hold baggage: stay at the screening point and follow instructions from security or airline staff immediately.
What happens at the checkpoint
Screening agents will isolate the hold bag, remove the item and move it to an explosives/hazmat-safe area for inspection. Expect a secondary screening that typically lasts 10–45 minutes; longer if fire‑safety teams are summoned. Security may ask for proof of ownership, purchase receipts or device serial numbers. Photograph any removed items only if staff permit; otherwise document details verbally and request a written incident note.
Possible immediate outcomes: 1) item transferred to the cabin at the gate if limits and airline policy allow and passenger remains in terminal; 2) item confiscated and retained for hazardous‑materials disposal; 3) item returned to passenger after inspection with instructions for safe carriage. A flight delay can occur if removal requires fire‑safety intervention or regulatory reporting.
Actions and follow‑up for the passenger
Ask for a written report or reference number from the security or airline representative before leaving the checkpoint. Keep photos of the original bag packing, receipts and device serials; these speed any claims for damaged or destroyed items. If the item is confiscated, request documentation that specifies whether it was disposed of or retained and the legal basis. Contact the airline’s customer‑service and the airport lost & found within 24–48 hours; if civil penalties are alleged, seek the specific regulatory citation.
If relocation of the power cell to the cabin is permitted, carry it in the original packaging or insulated against short circuits, and place it in a carry‑on accessible at the gate. For travel gear that eases gate transfers and onboard storage consult best luggage backpack with wheeled and best luggage for sicily.
