How to Package and Declare Dangerous Goods for Air Transport out of Sydney

Dangerous goods are items that could put people, aircraft or property at risk during a flight. The term sounds dramatic, but it covers many ordinary products: phone and laptop batteries, perfume, nail polish, hand sanitiser, paint, cleaning chemicals, camping gas and even some medical supplies. Every day, large volumes of these goods leave Sydney safely by air because they are prepared to strict international rules.

This guide explains how dangerous goods are regulated, how to classify and pack them, what documents you need and how to avoid common mistakes. It is part of our wider Air Freight Sydney guide.

Who sets the rules?

International rules for carrying dangerous goods by air are based on the ICAO Technical Instructions. Airlines and shippers worldwide use the IATA Dangerous Goods Regulations (DGR), which include the ICAO requirements plus additional airline rules. The DGR is updated every year, and a new edition takes effect on 1 January.

In Australia, the Civil Aviation Safety Authority (CASA) regulates the carriage of dangerous goods by air. CASA sets training requirements, investigates incidents and can take action, including prosecution, when rules are broken. Individual airlines may also apply their own, stricter variations, so always check the carrier's requirements.

The nine classes of dangerous goods

Some items are forbidden on aircraft altogether, and others may travel only on cargo aircraft, not on passenger flights. Our guide to prohibited and restricted air freight items in NSW covers items that cannot fly at all.

Step 1: Identify and classify the goods

Start with the Safety Data Sheet (SDS) from the manufacturer. Section 14 of the SDS usually lists transport information, including the UN number, proper shipping name, hazard class and packing group.

• UN number. A four-digit number identifying the substance or article, for example UN3480 for lithium-ion batteries shipped on their own.
• Proper shipping name. The standard name used on documents and packages.
• Class or division. The type of hazard.
• Packing group. I, II or III, showing high, medium or low danger, where applicable.

Use these details to find the entry in the DGR list of dangerous goods, which tells you the quantity limits and the packing instruction to follow for passenger and cargo aircraft.

Step 2: Check quantity limits and aircraft type

Each entry sets maximum quantities per package. Some goods may only be carried on cargo aircraft and must be labelled "Cargo Aircraft Only". Others may qualify for limited quantity or excepted quantity provisions, which allow small amounts to travel with simpler packaging and fewer requirements.

From Sydney, many international routes carry cargo in the bellies of passenger aircraft, so cargo-only items may need to be booked on a freighter. Ask your forwarder early whether suitable capacity is available.

Step 3: Choose the right packaging

The packing instruction tells you exactly how the item must be packed. For most dangerous goods, this means UN specification packaging, which has been tested to withstand drops, stacking and pressure changes. UN packaging carries a mark showing the packaging type, the packing groups it is approved for and the testing details.

General packaging principles include:

• Use inner packagings that are compatible with the contents and closed securely.
• Add absorbent and cushioning material where required, particularly for liquids.
• Leave space in liquid containers for expansion at altitude.
• Do not pack incompatible dangerous goods together.
• Close packages exactly as the packaging manufacturer instructs.

Step 4: Mark and label each package

Every package must show the right marks and hazard labels so handlers can recognise the risk. Typical requirements include:

• The UN number and proper shipping name
• Shipper and consignee names and addresses
• The correct hazard label for the class
• Handling labels such as "Cargo Aircraft Only", orientation arrows or the lithium battery mark where required
• Net quantity where required

Remove or cover old labels from reused boxes. Conflicting labels are a common cause of rejection at the terminal.

Step 5: Complete the Shipper's Declaration

For most fully regulated dangerous goods, the shipper must complete a Shipper's Declaration for Dangerous Goods. It lists the UN number, proper shipping name, class, packing group, quantity, packing instruction and any required authorisations. It must be signed by a trained person, confirming the shipment complies with the regulations.

The air waybill must also indicate that the shipment contains dangerous goods. Mistakes on the declaration, even small ones, can lead to the consignment being refused.

Step 6: Book with a carrier that accepts dangerous goods

Not every forwarder or airline accepts every class of dangerous goods. Tell your forwarder exactly what you are shipping when you ask for a quote, and provide the SDS. The terminal will check each dangerous goods consignment against an acceptance checklist before accepting it. Additional acceptance fees apply, and shipments that are rejected and resubmitted may be charged again.

If you are new to exporting, our guide to the step-by-step export process from Sydney shows where dangerous goods checks fit into the wider shipment.

Lithium batteries: the most common challenge

Lithium batteries are among the most frequently shipped dangerous goods and the most frequently misdeclared. The rules depend on the battery chemistry, its size and how it is packed:

• Batteries on their own, such as spare power banks, are heavily restricted. Lithium-ion batteries shipped alone must travel on cargo aircraft and meet state-of-charge limits.
• Batteries packed with equipment, such as a spare battery in the same box as a laptop, have their own requirements.
• Batteries contained in equipment, such as a phone with its battery installed, are generally the least restricted.

Every battery type must have passed the UN 38.3 testing standard, and damaged or recalled batteries are forbidden on aircraft. Ask your supplier for the test summary before you ship.

Dry ice and perishables

Dry ice, used to keep goods frozen, is a Class 9 dangerous good because it releases carbon dioxide gas. Packages must allow the gas to escape and be marked with the net weight of dry ice. If you ship frozen food, vaccines or samples, read our guide to temperature-controlled air freight alongside this one.

Training requirements

Anyone who classifies, packs, marks, labels or signs the declaration for dangerous goods by air must be trained to a level appropriate to their role. In Australia, dangerous goods training must meet CASA's requirements, and training needs to be refreshed regularly. If your business ships dangerous goods only occasionally, it may be simpler to use a forwarder with trained staff who can prepare the shipment for you.

What happens if you get it wrong

Undeclared or incorrectly declared dangerous goods are a serious safety risk. Consequences can include:

• Rejection of the shipment and extra handling fees
• Delays while goods are repacked or returned
• Investigation by CASA and possible penalties or prosecution
• Loss of trading relationships with carriers and forwarders

Other common dangerous goods from Sydney

Beyond batteries and dry ice, Sydney shippers regularly send:

• Cosmetics and personal care products, such as nail polish, hairspray and alcohol-based fragrances, which are often flammable
• Paints, inks and adhesives, which may be flammable or toxic
• Diagnostic specimens, which fall under specific packing instructions for biological substances
• Machinery and engines, which may contain fuel residue or batteries
• Magnetised material, such as large speakers, which can affect aircraft navigation equipment

Hidden dangerous goods are a particular concern. Items described as "tools", "spare parts" or "cosmetics" can contain hazardous components. Terminal staff are trained to question vague descriptions, so describe your goods accurately from the start.

Frequently asked questions

Can I ship a laptop overseas by air cargo?

Yes. A laptop with its battery installed is generally one of the least restricted lithium battery shipments, but it must still be packed and marked correctly, and the battery must meet UN 38.3 testing requirements.

Can I send perfume overseas by air?

Yes, but perfume is usually a Class 3 flammable liquid. Small quantities may qualify for limited quantity rules, while larger amounts need full dangerous goods preparation.

Are the rules the same for domestic flights?

Yes. The same dangerous goods rules apply to domestic air freight within Australia.

If you are unsure whether a product is a dangerous good, treat it as one until you have confirmed otherwise. Ask the manufacturer for a Safety Data Sheet and have a trained person review it before booking.

Safety first, every time

Shipping dangerous goods by air from Sydney is routine when it is done properly. Identify the goods, follow the packing instruction exactly, label clearly, declare honestly and work with trained people. For more on air cargo in the city, visit our main Air Freight Sydney guide.