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Dangerous Goods by Air: Cost and Compliance Tips for Australia (2025)

Shipping dangerous goods (DG) by air in Australia involves more than just packaging—it requires compliance with IATA, CASA, and carrier-specific rules, plus added cost layers. This guide walks through DG classifications, documentation, safety procedures, and how to manage costs in 2025.


1. What Are Dangerous Goods in Air Freight?

Dangerous goods are items or substances that pose risk to health, safety, property, or the environment during transport. According to IATA DGR (Dangerous Goods Regulations), there are 9 classes of DG:

  1. Explosives

  2. Gases

  3. Flammable liquids

  4. Flammable solids

  5. Oxidising substances

  6. Toxic & infectious substances

  7. Radioactive material

  8. Corrosives

  9. Miscellaneous (e.g., lithium batteries, magnetised material)

Australia aligns with ICAO and CASA rules, so understanding these classes is critical before shipping.


2. Who Can Ship Dangerous Goods?

Only trained and certified entities can prepare and lodge DG shipments by air. This includes:

  • Certified DG Shippers (trained per IATA DGR)

  • Known Consignors (approved by Australian Government)

  • Licensed Freight Forwarders with DG handling accreditation

Airlines will refuse non-compliant cargo—no exceptions.


3. Cost Factors for Dangerous Goods Air Freight

What Makes DG More Expensive?

Cost ComponentDescription
Handling FeesCarriers charge DG-specific handling surcharges (AUD $60–$250)
Special PackagingUN-rated drums, absorbent liners, DG labels, overpacks
DocumentationShipper’s Declaration for Dangerous Goods (AUD $45–$80)
Training & ComplianceOngoing certification and software tools
Limited Carrier OptionsNot all flights or lanes accept DG cargo

Average premium: 20–70% above standard air freight rate, depending on class and routing.


4. Required Documents for DG Shipments

To comply with IATA & CASA standards, you’ll need:

  • Air Waybill (AWB)

  • Shipper’s Declaration for Dangerous Goods

  • Material Safety Data Sheet (MSDS)

  • Commercial Invoice & Packing List

  • UN Certification Labels & Marks

  • Emergency Contact Details (AU-based)

Always double-check destination country rules—some add their own bans or conditions.


5. Packaging and Labelling Rules

Dangerous goods must be packaged per IATA Packing Instructions (PI) and labeled with:

  • Correct UN Number (e.g. UN3480 for lithium-ion batteries)

  • Class-specific hazard label

  • Orientation arrows and “Cargo Aircraft Only” if applicable

  • Overpack markings when bundling

Use only UN-certified packaging suppliers for compliance.


6. High-Risk Categories in Australia

These DG categories commonly ship via air and require special attention:

  • Lithium Batteries (UN3480, UN3481) – Common in electronics, subject to PI965-PI970

  • Medical Samples (UN3373) – Biological substances; used in pathology

  • Flammable Liquids (UN1993, UN1263) – Paints, solvents, fuels

  • Corrosives (UN1760) – Acids and industrial cleaners

Some mining and exploration clients also move small explosives, subject to federal clearance.


7. Tips for Reducing DG Air Freight Costs

  • Pre-book with specialist carriers (Qantas Freight, DHL, CargoMaster)

  • Bundle shipments under a single overpack to reduce labels & declarations

  • Use hybrid lanes – Air for DG core, sea/road for ancillaries

  • Get IATA-certified in-house staff to skip third-party fees

  • Avoid rejections by double-checking MSDS expiry and PI conformity


8. Regulatory Authorities in Australia

AuthorityRole
CASAOversees aviation safety and DG air regulations
IATAPublishes Dangerous Goods Regulations (DGR) yearly
ABF (Border Force)Inspects inbound DG shipments
DAFFReviews biohazard and quarantine cargo

Failure to comply can result in fines up to AUD $300,000 and aircraft diversion.


9. Conclusion

Shipping dangerous goods by air requires planning, certification, and precision. But with the right forwarder, accurate documents, and compliant packaging, Australian shippers can safely move DG with confidence—even under urgent timelines.

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Written by: Michael Lawson

Michael Lawson is a veteran air freight consultant with over 25 years of experience across Australia and the Asia-Pacific region. He specializes in urgent cargo, charter flights, and remote logistics for industries such as mining, medical, and FMCG.