How to Ship Dangerous Goods by Air: IATA DGR Guide

Introduction to Shipping Dangerous Goods by Air The experts at Private Jets Connect break down the key points below.

Air transport of dangerous goods is one of the most heavily regulated aspects of the freight industry. Every year, millions of tonnes of classified hazardous products travel by air: industrial chemicals, lithium batteries, medical specimens, compressed gases, paints, aerosols, and many others.

The regulations are strict for a simple reason: an incident involving dangerous goods in flight can have catastrophic consequences. Aviation history includes several accidents directly linked to undeclared or improperly packaged dangerous goods.

This guide details the procedures, classifications, and requirements for shipping hazardous materials by air in compliance with international regulations.

The Regulatory Framework

ICAO Annexes

The International Civil Aviation Organization (ICAO) defines the foundational rules in Annex 18 of the Chicago Convention and the Technical Instructions for the Safe Transport of Dangerous Goods by Air (Doc 9284). These texts constitute the international legal framework.

IATA DGR Regulations

IATA publishes the Dangerous Goods Regulations (DGR) annually, an operational manual that translates ICAO requirements into concrete procedures for airlines, forwarders, and shippers. The DGR is recognized as the worldwide industry reference.

National Regulations

Each country may impose additional restrictions beyond ICAO and IATA requirements. For instance, some airlines categorically refuse certain classes of dangerous goods, and some states require prior authorization procedures.

The 9 Classes of Dangerous Goods

The classification system divides dangerous goods into 9 main classes, each identified by a pictogram and number:

Some classes include divisions (e.g., Class 2.1 flammable gases, Class 2.2 non-flammable gases, Class 2.3 toxic gases) and packing groups (I, II, III) indicating the degree of hazard.

Packaging Requirements

UN-Certified Packaging

All dangerous goods shipped by air must be packed in UN-certified packaging – containers that have successfully passed the resistance tests defined by UN regulations. The UN marking (e.g., UN4G/Y26/S/…) indicates the type, performance level, and certification date.

IATA Packing Instructions

The DGR contains Packing Instructions (PI) specific to each product. Each PI defines:

• Authorized inner, intermediate, and outer packaging types
• Maximum quantities per package and per aircraft
• Cushioning and closure requirements
• Restrictions between cargo and passenger aircraft

For example, lithium-ion batteries are governed by PI 965 (standalone), PI 966 (packed in equipment), and PI 967 (contained in equipment), each with distinct power limits and requirements.

Regulatory Marking and Labeling

Every dangerous goods package must bear:

• The hazard label corresponding to the class (colored diamond)
• The UN number and proper shipping name
• Orientation arrows (this way up) for liquids
• The designation “Cargo Aircraft Only” (CAO) if prohibited on passenger aircraft
• The name and address of shipper and consignee

Mandatory Documentation

Shipper’s Declaration

The Shipper’s Declaration for Dangerous Goods (DGD) is a standardized form that the shipper must complete and sign for every shipment containing dangerous goods. This document certifies that the goods are correctly identified, classified, packaged, marked, and in condition for air transport.

The DGD contains:

• Product identification (UN number, proper shipping name, class, packing group)
• Quantity and packaging type
• Applicable packing instruction
• DGR-certified shipper contact details
• A signed compliance declaration

NOTOC

The NOTOC (Notification to Captain) is a document provided to the pilot-in-command before every flight carrying dangerous goods. It lists all hazardous materials on board, their location in the aircraft, and applicable emergency procedures.

Mandatory DGR Training

Handling and shipping dangerous goods by air requires specialized training. IATA defines several training categories based on the individual’s role:

• Category 1: shippers (shipment preparation)
• Category 3: freight forwarders and cargo agents
• Category 6: airline personnel (acceptance)
• Category 12: security personnel

Training must be delivered by an approved organization and renewed every 24 months. Lack of training exposes the company to criminal penalties and transport prohibition.

Prohibited Goods in Flight

Certain goods are strictly prohibited on all aircraft, whether cargo or passenger:

• Primed explosives and unauthorized pyrotechnic devices
• Toxic gases with a lethal concentration below 200 ppm
• Radioactive materials exceeding activity limits
• Damaged, defective, or recalled lithium batteries
• Devices containing both explosive and toxic substances

Other goods are authorized only on cargo aircraft (CAO - Cargo Aircraft Only), with higher quantity limits than those permitted on passenger aircraft.

The Acceptance Process

Cargo Agent Verification

Before each loading, the DGR-trained cargo agent conducts a thorough verification:

• Consistency between the DGD and physical contents
• Marking and labeling compliance
• Packaging integrity (no leaks, deformation, or corrosion)
• Maximum quantity limits per package and per aircraft
• Loading compatibility between different classes

Refusal of Acceptance

If a non-conformity is detected, the shipment is rejected and an incident report is filed. The most common non-conformities include: incorrectly completed DGD, non-UN-certified packaging, missing or incorrect labeling, and quantities exceeding authorized limits.

Organizing a Dangerous Goods Shipment

To ship hazardous materials by air, follow this process:

1. Identify your product precisely and determine its UN number, class, and packing group
2. Verify transport restrictions (CAO, limited quantities, exceptions)
3. Select UN-certified packaging matching the applicable packing instruction
4. Pack according to PI requirements, with secure cushioning and closure
5. Mark and label each package per DGR standards
6. Complete the Shipper’s Declaration (DGD) and the Air Waybill
7. Submit the shipment to an approved cargo agent for verification and acceptance

For complex or urgent shipments, a specialized broker like Private Jets Connect coordinates the entire process, from packaging to customs clearance.

Conclusion

Shipping dangerous goods by air is a highly regulated activity that tolerates no approximation. Compliance with ICAO and IATA DGR regulations is imperative for the safety of every participant in the transport chain.

For any dangerous goods air transport needs, trust Private Jets Connect. Our cargo freight expertise enables us to manage the most sensitive shipments in full regulatory compliance.

Need a cargo quote? Submit your request to Private Jets Connect for a tailored proposal.