Can CO2 Cartridges Go On A Plane? | Pack Smart

CO2 Cartridges And Air Travel Rules, In Plain English

CO2 cartridges sit in a tricky spot. Security looks at them as pressurized cylinders. Safety teams look at the gas class and size. That’s why you’ll see two different messages online. The TSA page for small compressed gas says full cylinders are a no. Yet flight safety rules make room for specific uses, with tight limits. The FAA PackSafe guidance explains when cylinders are accepted and when the TSA will still refuse them at screening.

When A CO2 Cartridge Is Allowed

Self-Inflating Life Vest: The Clear Exception

There’s a straight answer here. You may fly with one life vest containing up to two small CO2 cartridges, plus two spares. Either bag works. That’s the policy the TSA publishes for U.S. travel, and crews see it often at the checkpoint. Airlines accept it widely on both domestic and ocean routes. If space is tight in your bag, mount the cartridges in the vest to keep them together and reduce questions. You can point staff to the TSA life-vest page if anyone needs the exact wording.

Empty Cylinders: Valve Off, Visibly Empty

Bringing an empty cylinder is fine. The screening team needs a clear view that no gas remains. That usually means the valve is removed or left fully open with a gauge at zero. Pack it without caps or boots hiding the opening. If you carry tools, stash them separately so the cylinder stands on its own during inspection. Expect a quick visual check and a swab.

Small Cartridges With A Device: Airline Approval

Here’s where safety rules come into play. U.S. hazmat rules allow small non-flammable gas cartridges in or with a device when the air carrier agrees and specific limits are met. The limit most travelers meet is four cartridges per person, each no larger than 50 mL water capacity, packed with the device. Think mini inflators, not stand-alone spares. Some carriers accept them in checked bags only. Some say no across the board. Ask before you pack so you don’t lose gear at the counter. See 49 CFR 175.10(a)(25) for the exact language.

When A CO2 Cartridge Is Not Allowed

Loose sealed spares, without a life vest or device, draw a hard stop at screening. The same goes for paintball tanks filled with CO2. Staff can’t vent them for you. If your gear needs spares on arrival, buy local or ship ground. Soda maker cartridges fit the same pattern. If they’re full and not part of a device acceptance, they won’t pass.

How To Pack CO2 For Flying

Pack A Life Vest So It Flies Through

Keep the vest and spares in one pouch. Include a note with the rule line: “One life vest with up to two CO2 cartridges installed and two spares.” Place the pouch near the top of your bag so it’s easy to pull for inspection. Don’t tape over the cartridge heads. Screeners need to see them.

Show An Empty Cylinder Clearly

Remove the valve, plug, or head. If the head doesn’t come off, leave it open with no cap. Wipe the threads dry. A clear opening says “no pressure inside.” Add a paper towel to keep oil off clothes. Pack it along the side of the bag so it’s easy to reach.

Travel With A Device And Cartridges

Ask the airline for approval before you fly. Use the chat or the special goods desk. Keep the response in writing. Pack the device so it can’t fire. Use a trigger lock or remove the head. Put the cartridges in a small box next to the device. Label the box with the size, like “16 g CO2, Division 2.2” and keep the count at four or fewer per person.

What Size Counts As 50 mL?

The rules talk about “water capacity,” not grams of CO2. For these cartridges, 50 mL water capacity lines up with a 28 g CO2 cartridge. That’s the size you’ll see in many bike and lifejacket kits. Look for numbers stamped on the metal or printed on the blister card. If your cartridge is larger, it falls outside the small-cartridge allowance and can’t travel as a spare. When in doubt, bring the packaging and keep the label visible so staff can read the size without a long back-and-forth.

Taking CO2 Cartridges In Checked Luggage — Rules That Stick

Checked bags give you more room, not more freedom. The life vest allowance stays the same. Empty cylinders ride fine when they’re open and clean. Devices with small cartridges still need the carrier’s yes. Use a hard case when you can. Fill open space with soft gear so cylinders don’t bang around. Add your name and phone inside the case in case a ramp agent needs to reach you.

International And Airline Differences

Rules share a common base, yet carriers can set stricter terms. IATA’s table gives the same small-cartridge limits many crews use worldwide: up to four cartridges per person, each no larger than 50 mL water capacity, with a device, and subject to operator approval. UK advice mirrors that line for lifejackets. A few airlines ban the device path entirely even on long-haul routes. That’s their call. If your trip crosses multiple carriers, each one has a vote.

Before you book, search your airline’s dangerous goods page for “co2” or “gas cartridge.” If the site is light on detail, message support and ask for a short reply in writing. Bring that note to the counter. Keep calm if a staffer isn’t sure. Ask for a lead agent or a duty manager. Your goal is a quick, polite review of the policy so you can check in and head to the gate. For broader context, see the UK CAA lifejacket guidance and IATA’s passenger rules summary; the older public table shows the same 4×50 mL with-device pattern (Table 2.3.A).

Step-By-Step Checklist

1. Decide which lane you fit: life vest, empty cylinder, or device with approval.
2. Print the rule pages you need and keep them with your boarding pass.
3. Group cartridges with the vest or the device; don’t scatter them through the bag.
4. Leave openings visible and keep labels readable.
5. Use pouches and boxes so items don’t roll or trigger the device.
6. Arrive a little early and politely tell the agent you have CO2 under the passenger rules right at check-in.

Shipping Or Renting Instead

Skipping cylinders can be simpler. Many dive, paddle, and bike shops sell or rent cartridges at your stop. Ground shipping works too—use a sturdy box, add padding, and pick a carrier that accepts pressurized gas. Mark the contents so the parcel doesn’t bounce back.

Common Mistakes That Trigger Confiscation

Packing Loose Sealed Spares

They look harmless in a saddle bag or tool roll. At screening they’re still pressurized cylinders with no approved device. They end up in the bin. Don’t bring them.

Leaving A Tank Half Empty

A gauge at 200 psi looks better than 800 psi, yet it doesn’t meet the rule. Staff can’t release gas for you. Ship it or drain and disassemble before you fly.

Hiding The Valve Under Caps Or Tape

Covering the opening slows the check and makes officers suspicious. Leave the opening exposed so they can see daylight. That shortens the inspection and keeps the line moving.

Skipping Airline Approval For Devices

You might get lucky once. The next station could take everything. Ask for approval and keep the email handy. It’s a two-minute task that saves a lot of hassle.

Bottom Line Rules For CO2 And Planes

Two clear wins: a life vest with two small cartridges fitted and two spares, or any cylinder that’s proven empty. Everything else runs through the device path with airline approval and small size limits. If the item doesn’t fit those lanes, don’t take it to the airport. Buy at your destination, rent, or ship by ground. That keeps your trip smooth and your gear intact.