The Complete Guide to IATA Dangerous Goods Regulations

Whether you ship a single phone battery or a pallet of paint, the IATA Dangerous Goods Regulations (DGR) determine exactly how that consignment must be classified, packed, marked, labelled and documented before it goes anywhere near an aircraft. The manual is the airlines’ legally-binding rulebook, built on ICAO and UN requirements and enforced by civil aviation authorities worldwide. Misapply it and you risk rejected cargo, fines, or worse—a preventable incident at 35,000 feet.

This practical guide translates the 1,200-page DGR into plain English. You’ll see how the book is organised, follow a step-by-step shipment walkthrough, learn the quirks of lithium batteries and infectious substances, spot pitfalls that trip up even experienced shippers, and understand the training and update cycle that keeps your procedures current. By the end, you’ll know exactly where to find each rule and how to apply it with confidence.

What the IATA Dangerous Goods Regulations Cover and Why They Matter

From phone batteries to radioactive sources, the IATA Dangerous Goods Regulations define how every hazardous item must be prepared for flight. Knowing their reach prevents injuries, delays and penalties.

Purpose and Scope of the DGR

Their objective is straightforward: eliminate in-flight risk from dangerous goods. The book walks users through classification, packing, marking, labelling, documentation and airline acceptance for each UN-listed substance. Failure to comply invites shipment refusal, heavy fines or prosecution.

Legal Status and Relationship to ICAO and UN Rules

Built on the UN Model Regulations and codified in ICAO’s Technical Instructions, the DGR becomes contractually binding once an airline accepts a booking. IATA adds stricter rules—e.g., lithium-ion batteries limited to 30 % state-of-charge. Civil aviation authorities worldwide enforce compliance.

Comparing DGR with Other Modal Codes (ADR, IMDG, RID)

Road (ADR) and sea (IMDG) codes differ; what’s legal there may be banned by air. Key gaps:

• Shipper’s Declaration vs multimodal DGD
• Tighter quantity limits (Class 3: 1 L by air, 5 L by road)
• 95 kPa pressure test unique to air packaging

Multimodal businesses therefore need separate procedures.

Inside the DGR Manual: Chapters, Lists and Tables Explained

Even seasoned shippers can feel lost in the 1,200-page maze of the IATA Dangerous Goods Regulations. Knowing where each rule lives turns a frantic page-flip into a two-minute lookup and, more importantly, stops compliance errors before they leave the desk.

Overview of the 11 Chapters and Appendices

The manual is split into eleven logically-sequenced chapters, moving from big-picture legality to the nuts and bolts of documentation, followed by supporting appendices.

1. Applicability – who and what the rules cover
2. Limitations – forbidden goods, passenger allowances
3. Classification – hazard classes, packing groups
4. Identification – UN numbers, Proper Shipping Names
5. Packing – instructions and performance tests
6. Packaging Specifications – UN codes, inner receptacles
7. Marking & Labelling – designs, sizes, placement
8. Documentation – Shipper’s Declaration, air waybill text
9. Handling – segregation, storage, emergency response
10. Radioactive Materials – dedicated rules, TI limits
11. Compliance & Training – CBTA, record keeping
    Appendices add definitions, conversion tables, state/operator variations and sample forms.

The Nine Classes of Dangerous Goods

Quick reference table:

Subsidiary risks and packing groups refine these broad headings when you consult the Dangerous Goods List.

Key Reference Tables Every Shipper Uses

Table 4.2 is the manual’s heartbeat. Read it left to right: UN number → proper name → class/sub-risk → packing group → passenger/ cargo quantity limits → packing instruction. Tables 2.3.A/B set passenger-baggage limits, while Section 5’s special provisions and Chapter 1’s operator variations flag carrier-specific tweaks.

Amendments, Addenda and Corrigenda

A fresh edition lands each 1 January. IATA issues interim addenda online; mark release alerts in your compliance calendar and update SOPs within 30 days to stay audit-ready.

Preparing and Offering a Dangerous Goods Shipment Step by Step

The IATA Dangerous Goods Regulations set out a strict, linear workflow: classify the substance, select the right packaging, mark and label the package, issue the paperwork, then pass the freight through airline acceptance. Skipping or re-ordering stages is the fast lane to rejections and fines, so treat the list below as a non-negotiable countdown.

Classification and Identification

Start with the Safety Data Sheet or test data. Pinpoint:

1. Primary hazard (flash point, toxicity, activity).
2. UN number and Proper Shipping Name – e.g. UN 1263 PAINT.
3. Subsidiary risk and Packing Group (I, II or III).
   Confirm against Table 4.2; if several entries fit, pick the most specific. Record the result in your internal DG register—the inspector will ask.

Selecting Approved Packaging

Match the substance to the Packing Instruction shown in Table 4.2. Lithium-ion cells alone? PI 965. Paint, PG II? PI 353. Packaging must carry a UN spec code such as 4G/X25/S/25/GB/1234, proving it passed drop and pressure tests. Check:

• Inner receptacle limits
• Cushioning compatibility
• Need for combination or single packaging
  Overpack? Affix “OVERPACK” in 12 mm text and repeat marks visible inside.

Marking and Labelling Requirements

Apply before closure, never afterwards. Minimum outer marks:

• UN number and Proper Shipping Name
• Gross and net quantity in kg or L
• Sender/consignee details (if no overpack)
• Orientation arrows for liquids
  Labels (100 × 100 mm unless noted): primary hazard, subsidiary risk, handling (e.g. lithium battery mark, “Cargo Aircraft Only”). Keep 12 mm clearance from edges.

Documentation: Shipper’s Declaration and Air Waybill

Complete the red-bordered Shipper’s Declaration: sequence UN number → PSN → class/division → subsidiary risk → packing group → quantity/packing type → “–” → packing instruction. Use a point not a comma for decimals (1.5 L). The air waybill needs the “Dangerous goods as per attached DGD” statement or “Not restricted” note for Section II batteries.

Acceptance Checks and Airline Variations

The operator reviews an 11-point checklist: documentation accuracy, packaging integrity, label placement, quantity limits, pilot notification. Common fails: wrong edition cited, missing closure torque, net weight mismatch. Always pre-screen State (e.g. “USG-16”) and Operator (e.g. “AF-01”) variations in Section 2—rules can tighten without notice. A quick email to the carrier saves a costly return.

Special Provisions for High-Profile Hazardous Items

Some commodities attract extra pages of rules because of their accident history or public-safety profile. The DGR carves these out in specific packing instructions and notes. Treat the shortcuts with the same discipline as full-scale dangerous goods—airlines will still refuse anything that is even slightly off-spec.

Lithium Batteries (Section II, PI 965–970)

• UN 3480/3481 (lithium-ion) and UN 3090/3091 (lithium-metal) live in PI 965–970.
• Section II lets you ship small cells (≤ 20 Wh or 100 Wh battery) without a Shipper’s Declaration, provided:
  • State of charge ≤ 30%.
  • Max 2 Section II packages per consignment and 1 overpack.
  • Apply the lithium battery mark (UN 3481 + phone symbol, 135 × 113 mm).
• Larger batteries fall into Section IA/IB and need full paperwork.

Infectious Substances and Dry Ice

• Category A: UN 2814/2900, PI 602, full declaration.
• Category B: UN 3373, PI 650, no DGD but triple packaging mandatory.
• Dry ice (UN 1845, Class 9) is often the refrigerant; mark net weight in kg beside the dry-ice label and ensure vents prevent pressure build-up.

Radioactive Materials by Air

Packages are graded I-white, II-yellow or III-yellow using the Transport Index (TI) formula:
TI = (max mSv/h at 1 m) × 100.
Category II and III need the TI on the label and may trigger routing restrictions or carrier pre-approval.

Limited and Excepted Quantities

Limited Quantities permit up to 1 L/1 kg per inner receptacle (varies by class) under the Y-diamond symbol and remove the Shipper’s Declaration. Excepted Quantities drop limits further—often 30 ml or 30 g—and use the E-code mark. Convert volume to net mass (density × volume) to stay inside the threshold.

Typical Compliance Errors and How to Avoid Them

Even with the IATA Dangerous Goods Regulations open on the desk, routine slip-ups still derail shipments. The majority fit into four predictable categories—spot them early and you save money, time and goodwill.

Misclassification and Incorrect UN Numbers

• Treating high-flash paint as UN 1263 when test data show it belongs under “flammable liquid n.o.s.”
• Assigning “lithium battery contained in equipment” (UN 3481) to a power bank shipped loose—really UN 3480.
• Choosing Packing Group II by habit; always check SDS Section 9 for flash point or toxicity to confirm the right group.

Packaging and Performance Test Failures

• Using a UN box certified for solids (S) to move liquids—pressure test missing, package rejected.
• Skipping closure torque values; airlines expect the figure written on the Shipper’s Declaration.
• Reusing fibreboard cartons after water damage—edge crush strength is gone, drop test will fail.

Documentation Mistakes That Lead to Rejection

• Decimal comma (“1,5 L”) instead of point (“1.5 L”) in quantity column.
• Forgetting the “OVERPACK USED” statement when marks are obscured.
• Citing an obsolete DGR edition; always update the reference line on 1 January.

Operational Errors During Handling and Loading

• Mixing Class 5.1 oxidisers with flammables in the same ULD—violates segregation chart.
• Allowing lithium battery freight to sit in direct sun; cell temperature may exceed the 60 °C limit.
• Affixing labels over closure seams—labels peel off, unreadable at acceptance.

Training and Competency Requirements Under the DGR

Rules mean nothing without trained people; the DGR demands role-specific, documented competence.

Who Must Be Trained and at What Level

A–H categories span shippers, packers, freight agents, airline acceptance staff, ground handlers, flight crew, security screeners and passenger-facing staff. Depth of knowledge scales with risk: Category A writes the declaration; Category H simply asks baggage questions.

From Traditional to Competency-Based Training and Assessment (CBTA)

Hour-count certificates are being replaced by Competency-Based Training and Assessment. Employers analyse each role, set measurable outcomes, train with realistic scenarios, then keep evidence—tests or observed tasks—that the worker can perform safely and repeatedly.

Recurrent Training, Records and Oversight

Competence expires. Reassessment is due every 24 months or sooner after a regulation change or incident. Records—course syllabus, results, assessor signature—must be retained for at least three years and be available to the civil aviation authority on request.

Selecting an Approved Dangerous Goods Training Provider

Pick a provider offering the current DGR edition, CBTA alignment and instructors with real shipping experience. Blended delivery—classroom, virtual or e-learning—minimises downtime, while post-course helplines guard against first-shipment nerves. Logicom Hub provides all three plus UK-wide scheduling.

Keeping Your Procedures Current: Tools and Resources

Regulations move every year, software evolves even faster, and auditors expect you to keep pace. The tools below make that upkeep a manageable, calendar-driven routine.

Annual Edition Cycle and Effective Dates

A new DGR takes effect on 1 January; the old one becomes history overnight. Order the next edition in October, brief staff in November, and switch SOP references the first working day of January.

Accessing the Manual: Print, Digital, and Mobile Options

Pick the format that matches your workflow:

• Spiral-bound hard copy for ramp-side scribbles
• eDGR subscription with searchable text and hyperlinks
• Mobile app for spot checks during acceptance

Digital Aids: IATA DG AutoCheck and Third-Party Software

AutoCheck validates each Shipper’s Declaration against the live database, flags errors, and prints compliant labels. Freight-management suites integrate the same data to auto-populate airwaybills and generate pilot notifications.

Feeding Updates into Company SOPs

Adopt a four-step loop: collect addenda, gap-analyse existing procedures, update forms and training slides, then log changes with date, edition and responsible person. Rinse and repeat after every addendum or incident review.

Key Takeaways

• Know the structure of the IATA Dangerous Goods Regulations so you can find the right rule in seconds.
• Follow the five-step preparation flow: classify, pack, mark/label, document, airline acceptance.
• Keep staff competent with CBTA-aligned training refreshed every 24 months.
• Update manuals, SOPs and software each January—and after every addendum.

Master these points and compliance becomes routine rather than roulette. Need practical, regulator-recognised IATA training? Visit Logicom Hub and turn the rulebook into everyday confidence.