Dangerous Goods (DG) move through Australia’s domestic air network every day, yet many shippers still underestimate the strict protocols that govern this category. Airlines, ground handlers, and regulators like the Civil Aviation Safety Authority (CASA) enforce precise procedures to keep aircraft, crew, and cargo secure. Misdeclared or incorrectly packed DG can cause flight delays, fines, or outright rejection at the terminal. This guide breaks down the rules, operational realities, and the level of detail required before DG freight can be accepted for uplift.
For shippers moving DG between major hubs, the corridor between Melbourne and Perth is one of the busiest. For broader context on this route, refer to the pillar page: Air Freight Melbourne to Perth.
1. What Counts as Dangerous Goods?
Dangerous Goods are materials or substances that pose risks to health, safety, property, or the environment when transported by air. They are classified under the IATA Dangerous Goods Regulations (DGR) and the UN classification system. Shippers often assume DG only refers to chemicals, but the list is far broader.
Common DG types moved domestically include:
- Class 2 – Gases (compressed oxygen, aerosols, LPG cylinders)
- Class 3 – Flammable liquids (paints, solvents, fuel samples)
- Class 4 – Flammable solids
- Class 5 – Oxidizing substances
- Class 6 – Toxic and infectious substances
- Class 8 – Corrosives (battery acid, certain cleaning agents)
- Class 9 – Miscellaneous DG (lithium batteries, dry ice, magnetized materials)
Even small consumer items can be regulated—for example, lithium-ion batteries inside electronics are subject to strict packaging and state-of-charge requirements.
2. CASA and IATA: The Regulatory Backbone
Domestic DG air transport in Australia is governed by:
- CASA (Civil Aviation Safety Authority) – Australia’s primary aviation regulator
- DHB (Dangerous Goods by Air) – national compliance guidance
- IATA DGR – the global technical standard adopted by airlines
CASA mandates that shippers and freight forwarders handling DG must be properly trained, certified, and compliant with the most recent IATA DGR edition. Airlines may apply stricter internal policies than IATA, particularly on domestic flights using narrow-body aircraft such as the Boeing 737.
3. Documentation Required for DG Shipments
Dangerous Goods acceptance relies heavily on documentation accuracy. A single error can cause a shipment to be rejected.
Required documents commonly include:
- Shipper’s Declaration for Dangerous Goods (DGD)
- Air Waybill (AWB) with correct DG details
- Safety Data Sheet (SDS)
- Packing certificate and UN specification markings
- Test reports for certain DG types (especially lithium batteries)
Ground handlers verify every line of a DGD, including UN number, proper shipping name, classification, packing instruction, and quantity limits. Discrepancies are one of the most common reasons DG freight gets delayed.
4. Packaging and Labelling Compliance
Dangerous Goods must be packed using UN-approved packaging that meets performance standards such as impact resistance, pressure testing, and leakproof integrity. Labels and markings must remain fully visible after handling.
Key packaging requirements include:
- UN spec markings on outer packaging
- Proper Shipping Name displayed clearly
- Hazard labels (Class labels, subsidiary risks)
- Handling labels such as “Cargo Aircraft Only” or “Lithium Battery”
- Orientation arrows when required
Improper packaging is a major reason DG is rejected during acceptance. Airlines and handlers follow strict checklists and are not permitted to overlook missing labels or damaged packaging.
5. Airline Acceptance Rules: Not All DG Is Allowed
Contrary to common belief, airlines do not accept all DG classes on domestic flights. Acceptance depends on aircraft type, available ventilation, carrier policy, and the nature of the cargo.
For example:
- Class 1 (Explosives) → Almost always prohibited
- Class 2.1 (Flammable gas) → Restricted to certain quantities
- Lithium batteries → Strict state-of-charge and packaging requirements
- Cargo Aircraft Only (CAO) items may not fly on passenger aircraft
Wide-body aircraft such as the Airbus A330 offer better compatibility for certain DG categories, but availability on domestic routes is inconsistent. Most Melbourne–Perth flights use Boeing 737s, which limits what can be accepted on short notice.
6. Screening and Handling Challenges
All DG shipments must undergo security screening, typically X-ray, ETD, or manual inspection. Some DG types cannot be screened by X-ray, which introduces delays while handlers perform alternative checks.
Operational challenges include:
- High congestion at MEL during peak hours
- Manual checking for certain DG items
- Incompatibility with other cargo on the same ULD
- Load-planning restrictions for weight distribution and ventilation
These constraints mean that DG shipments rarely qualify for same-day uplift unless pre-booked and tendered early.
7. Common Reasons DG Gets Delayed or Rejected
Even experienced shippers encounter setbacks. The most common issues include:
- Incorrect or incomplete shipper’s declaration
- Damaged or unapproved packaging
- Missing hazard labels or UN markings
- Airline-imposed embargoes on certain DG classes
- Late delivery to the freight terminal
- Mismatched SDS information
- Incompatibility with aircraft type
Handlers are trained to reject, not “fix,” problematic DG cargo. A repack or re-label may take hours depending on availability and compliance checks.
8. How to Improve DG Acceptance Success
Shippers can significantly reduce delays by following these best practices:
- Always pre-book DG shipments with the carrier
- Deliver cargo early to avoid peak congestion
- Double-check documentation against the IATA DGR
- Use certified DG specialists for packaging and declarations
- Confirm airline restrictions before preparing the shipment
- Keep SDS documents updated and accessible
DG acceptance success hinges on preparation. The earlier handlers can begin documentation and packaging checks, the higher the likelihood of uplift.
Conclusion
Dangerous Goods remain one of the most regulated categories in domestic air freight. Moving DG from Melbourne to Perth—or anywhere in Australia—requires precise documentation, compliant packaging, and early tender times. Airlines prioritise safety above all else, and non-compliant DG is rejected without exception. By understanding the rules and operational realities, shippers can move hazardous materials safely and efficiently across Australia’s domestic air network.