How to Ship Dangerous Goods by Air — The Complete Guide

Let's be honest — most shipment rejections at the airport happen because someone assumed dangerous goods (DG) work like regular cargo. They don't. Air is the strictest mode for DG, and if you get even one detail wrong, your shipment won't fly. Simple as that.

We handle DG air freight out of Delhi, Mumbai, and Bangalore every week. This guide is based on what actually happens at acceptance counters, not just what the rulebook says.

First, Know What You're Shipping

Everything starts with classification. IATA divides dangerous goods into 9 classes:

• Class 1 — Explosives
• Class 2 — Gases (flammable, non-flammable, toxic)
• Class 3 — Flammable Liquids
• Class 4 — Flammable Solids
• Class 5 — Oxidising Substances & Organic Peroxides
• Class 6 — Toxic & Infectious Substances
• Class 7 — Radioactive Material
• Class 8 — Corrosives
• Class 9 — Miscellaneous (lithium batteries fall here)

Each class has sub-divisions and packing groups — I, II, or III — that tell you how dangerous the substance is. Packing Group I means highest danger. Get the packing group wrong, and your packaging certification becomes invalid.

The Shipper's Declaration Is Not Optional

This is the document that trips up most first-time DG shippers. The Shipper's Declaration for Dangerous Goods (also called SHDG or Air Waybill DG declaration) must be completed in English, printed on specific paper, and signed by a certified DG shipper.

Not typed and printed by anyone. Signed by someone who has completed an IATA DG CAT 6 or equivalent training. Airlines check this. If the signatory's training is expired — even by a day — the shipment gets rejected.

Packaging That Actually Passes

You need UN-certified packaging. The marking on the box must match the packing instruction in the IATA DGR table for your specific UN number. For example, if you're shipping lithium ion batteries (UN3480), Packing Instruction 965 applies. Deviate from it and you're rejected at acceptance.

The outer packaging must also be clearly labelled with the hazard diamond, UN number, proper shipping name, and — for Class 7 — a radiation level marking.

What Airlines Actually Check at Acceptance

When you bring a DG shipment to an airline, they run through a checklist. They check the declaration matches the actual contents, that the net quantity per package doesn't exceed the PI limit, that the packaging is undamaged, and that the shipper's training certificate is valid.

Air India, Emirates, and Qatar Airways all have strict acceptance desks. Budget carriers often refuse DG entirely. Always confirm with the airline before booking.

Hidden Restrictions Worth Knowing

Some goods are forbidden on passenger aircraft but allowed on cargo-only flights. Some are forbidden altogether regardless of how well they're packed. Class 1 explosives and most Class 7 radioactive materials, for instance, need special permits from DGCA even before you approach the airline.

The IATA DGR 65th Edition (2024) is the reference. If you're shipping in India, DGCA's Civil Aviation Requirements (CAR) Section 8 Series X adds domestic requirements on top. Both apply simultaneously.

One Last Thing

Don't assume your freight forwarder knows DG regulations in detail. Many don't. Always ask specifically whether they have IATA DG certified staff on their acceptance team. If they hesitate, that's your answer.

We're happy to walk you through your specific shipment before it goes wrong at the airport. That's what we do.