Lithium Battery Risks on Aircraft

Lithium batteries power much of our modern lives — from smartphones and laptops to power banks and portable chargers. But while they’re essential for keeping devices running, they also present unique safety risks when carried aboard aircraft. The Federal Aviation Administration (FAA) recently issued a Safety Alert for Operators (SAFO) highlighting the potential dangers and best practices for managing lithium batteries in passenger compartments.

The full SAFO can be found HERE.

Why Lithium Batteries Require Special Attention

Lithium batteries can act as ignition sources. In rare cases, they can experience thermal runaway, a self-sustaining, uncontrolled increase in pressure and temperature that may lead to fire. Because passengers often store these batteries in overhead bins or carry-on baggage, they may be hidden and difficult to access. Delays in detecting thermal runaway can increase the severity of an incident, making proper risk management essential.

FAA Recommendations for Operators

The FAA emphasizes that airlines and operators should adopt robust safety risk management processes as outlined in 14 CFR Part 5, Subpart C. This includes identifying potential hazards associated with lithium batteries and implementing mitigation strategies. Here’s what operators are encouraged to do:

Review and Enhance Risk Management

Identify all potential hazards from carrying lithium batteries in passenger compartments.
• Consider storage locations that may not be visible or easily accessible, such as overhead bins.

Update Firefighting Procedures

Train crew to recognize different stages of lithium battery thermal runaway, from smoke to flame.
• Assess onboard safety equipment — fire extinguishers, water sources, and containment devices — for effectiveness.
• Review procedures to minimize smoke inhalation risks for passengers and crew.

Educate Passengers and Crew

Clearly communicate what lithium batteries are, where they’re found, and the risks of thermal runaway.
• Encourage passengers to carry lithium batteries in visible, accessible locations.
• Guide safe handling and storage, such as protecting terminals, avoiding crushing, and storing batteries in plastic bags or protective cases.
• Instruct passengers to alert the crew immediately if a battery begins to overheat or smoke.

Effective Response to Thermal Runaway Events

Traditional firefighting tools, such as Halon extinguishers, can temporarily suppress flames but cannot stop a thermal runaway reaction. The FAA stresses that large amounts of water are the most effective method for cooling the battery and preventing further escalation. Proper training for the crew is essential to ensure a rapid and effective response in the event of a lithium battery fire.

Additional FAA Resources

Operators are encouraged to review existing FAA guidance, including:

AC 120-92: Safety Management Systems for Aviation Service Providers
AC 120-80: Firefighting of General and High-Energy In-Flight Fires
Past SAFOs on lithium battery carriage and firefighting
Air Carrier Safety Training Videos on PED firefighting (FAA Resource)

Keeping Air Travel Safe

While incidents involving lithium batteries on aircraft are rare, the risks are real. Airlines and operators must take proactive measures, from revising firefighting procedures to educating passengers and crew. Passengers also play a crucial role by following safe handling practices and promptly reporting any battery issues. By understanding these risks and implementing effective mitigation strategies, we can all help ensure that air travel remains safe for everyone on board.

Need Help Shipping Batteries Safely?

ICC Compliance Center helps organizations navigate lithium battery shipping requirements. If you need support with classification, packaging instructions, marking and labeling, training programs, documentation review, or proof of compliance, we are here to help. Our team of experts is just a call away for our customers at 855.734.5469 or send us an email, we’re happy to help.