Five ASEAN countries have tightened air‑freight regulations for lithium batteries—what exactly has changed? This article explains it all.

I. What exactly was changed? There are three core changes.

This policy was jointly issued by ASEAN‑STAR on July 11 and implemented simultaneously by the civil aviation authorities of five countries, fully aligning with IATA DGR Edition 67 and the latest UN38.3 Section 6.5 (IEC 62281:2026, Third Edition). There are three key changes, each of which is closely related to shipping:

01 The old version of the UN38.3 report has been completely invalidated; the new‑version testing has become the “pass” for air transport.

Under the previous regulations, UN38.3 reports from 2025 and earlier versions could still be used for customs clearance. However, the new rules mandate that, effective August 1, only the latest version 6.5 of the UN38.3 test report will be accepted. Key upgrades include enhanced vibration testing and thermal runaway simulations, which now replicate scenarios such as high-altitude turbulence, low-pressure expansion, and high-temperature self-ignition.

More critically, there is a strict threshold: test reports must be issued by laboratories accredited under the ASEAN MRA; test reports from ordinary domestic small-scale workshops will not be accepted. For standalone batteries and high‑power energy‑storage batteries, devices without the latest‑version report will be outright prohibited from being installed.

02 Battery State of Charge (SOC) is forcibly locked; shipments exceeding the threshold will be rejected without approval.

In the past, many shippers used to ship batteries fully charged; now, the five major ASEAN countries are uniformly enforcing stringent standards:

Lithium-ion batteries (power banks, energy storage cells, UN 3480): Remaining charge must be strictly ≤30%.

Built-in battery products such as mobile phones, tablets, and Bluetooth headphones (UN3481): High-power models are likewise limited to 30% charge.

Electric vehicles and portable energy storage devices (UN3556): The maximum charge limit has been reduced to 25%.

If the battery level exceeds the red line, and no airline has granted written special approval, the airport will seize the battery and prohibit it from being loaded onto the aircraft.

03 Electronic filing via online networks eliminates underreporting, and paper-based filing is being phased out.

The five countries have connected to the ASEAN Single Window (ASW) system, mandating the electronic submission of dangerous goods shipping declarations (e‑SDDG), and enabling online verification of customs declarations, air waybills, and test reports.

Customs authorities and airlines can instantly cross‑check declaration details against the actual goods and accompanying documents, enabling immediate detection of false or inaccurate declarations.

Real-time temperature monitoring at ground-level storage: when the ambient temperature of the stored goods exceeds 30°C, the system automatically flags them for isolation and quarantine, making it impossible to schedule loading.

II. Which products have been affected? Check whether your product is on the list.

The new regulations affect far more than just “pure batteries.” The following categories of goods are all caught in the crossfire:

01 Lithium-ion battery (UN3480) — The strictest category. It mandates that the state of charge be ≤30%, and a proof-of-charge document must be provided prior to export.

02 Battery-powered devices — Don’t assume that everything is fine just because “the battery is installed in the device.” Lithium batteries packaged together with the device (PI966) must also have a state of charge of no more than 30%.

03 Battery-Driven Vehicles — Including electric scooters, self-balancing vehicles, and the like, the 30% state-of-charge limit also applies.

04 Data Loggers and Cargo Tracking Devices — If the device contains a built-in lithium battery with a rated energy exceeding 20 Wh, compliance requirements must also be observed.

⚠️ Please note the power‑limit threshold: For air transport, the rated energy of a single lithium battery must not exceed 100 Wh. Batteries with a rated energy between 100 and 160 Wh require special approval from the airline; those exceeding 160 Wh are prohibited from air transport and must be shipped by sea.

III. What “extra acts” does each of the five countries have?

Although the new regulations are based on IATA’s unified standards, each country still has its own idiosyncrasies:

🇹🇭 Thailand

Lithium batteries entering Thailand require TISI certification. Portable batteries must comply with the new standard TIS 62133‑2:2022, while the previous standard TIS 2217‑2005 will be fully invalidated by the end of 2026.

🇻🇳 Vietnam

Lithium batteries must pass IEC 62133 and RNT testing. The description of goods on the Form E certificate of origin must be identical to that on the actual packing list—any minor discrepancy, such as labeling “lithium‑ion battery module” as “lithium battery accessory,” will result in the loss of tariff‑exemption eligibility.

🇸🇬 Singapore (the strictest in Southeast Asia)

The Civil Aviation Administration requires that all lithium batteries transported by air be declared in advance, packaged in antistatic materials, and limited to a maximum of 10 kg per package. In addition, Singapore is implementing a “Battery Passport” system.

🇲🇾 Malaysia

There are specific restrictions on the transportation routes for lithium batteries. Lithium‑polymer (LiPo) batteries with a capacity exceeding 100 Wh require airline approval, while those exceeding 160 Wh are strictly prohibited on passenger aircraft.

🇵🇭 Philippines

For battery-only shipments (UN 3480), the state of charge must be no more than 30%, and a certificate of state of charge must be provided.

IV. How to complete the declaration? Don’t let a single form hold up your entire shipment.

Required Documents List:

UN38.3 Test Report (Version 6.5, issued by an ASEAN MRA‑recognized laboratory)

Safety Data Sheet (SDS)

Dangerous Goods Shipment Declaration (e-SDDG)

Certificate of State of Charge

Hazard labels and markings for lithium batteries

Important Notes for Submission:

Lithium batteries must be declared uniformly as Class 9 hazardous materials.

The declaration form must clearly indicate the battery type, rated energy (Wh), and state of charge.

Some countries require bilingual signage (e.g., Cambodia requires Khmer and English).

The description of the goods must be identical to that on the packing list and the bill of lading.

V. How should the packaging be done? Just follow these few points, and you’ll be sure to get it right.

01 Preventing short circuits is the top priority. — Insulate the positive and negative terminals of each battery with adhesive tape, and package them individually in bags or rigid cardboard boxes to prevent short circuits caused by contact between batteries. For products with built-in batteries, ensure they are powered off.

02 There’s a Science to Outer Packaging — Use sturdy five-layer corrugated cardboard boxes. The outer cartons must be labeled with the lithium battery-specific marking and the UN 3480 Class 9 hazardous materials label.

03 Stacking Has Standards — For air transport of lithium batteries, the double‑stacking standard applies: the total pallet height must not exceed 1.6 meters, and the weight of the stack on top of a single container must be kept within 30 kg.

04 Drop Test — The packaging must pass a 1.2-meter drop test.

Written at the end

This time, the five ASEAN countries have simultaneously tightened their air‑freight regulations for lithium batteries, with an unprecedented level of stringency and scope. The requirements have been elevated—from UN 38.3 testing reports to SOC capacity limits, and from electronic filing and networked systems to country‑specific certification mandates—raising the compliance threshold across the board.

But look at it from another angle: once you’ve mastered the rules and streamlined the processes, you can actually stand out in this round of industry reshuffling—after all, with fewer players able to ship in full compliance, your opportunities will only grow.

Huijietong will continue to monitor policy developments in various countries, providing you with the latest and most accurate logistics compliance information. If you have any air freight shipping needs involving lithium batteries, please feel free to contact our expert team at any time!

This article is compiled based on official announcements, reports from reputable media outlets, and the latest policies of various countries. For specific procedures, please refer to the most recent requirements issued by airlines and the destination country.