Shipping lithium batteries – Frequently asked questions

The use of lithium batteries is growing exponentially – thanks to their lightweight design, performance, and relatively low cost.

However, shipping lithium batteries has proven dangerous, being blamed for several aircraft crashes and devastating fires if batteries are not handled, stored, or transported properly.

Whilst this has led to the rise of specialist packaging, including customised Zarges aluminium battery cases tested to UN standards, there are many misconceptions surrounding the topic. Many are also unaware that such stringent laws and guidelines even exist.

Whilst it may be helpful to read this beginner’s guide to the UN3048 and UN3090 regulations, this guide aims to answer the most frequently asked questions on this topic.

With so many questions about what is undoubtedly an extensive subject, this guide has been broken down into several sections.

Lithium batteries fall into two broad classifications: lithium metal batteries and lithium-ion batteries.

• Lithium metal batteries are generally single-use and contain metallic lithium.
• Lithium-ion batteries, in contrast, contain lithium, which is only present in an ionic form in the electrolyte. They are also rechargeable.

Yes, there are many different chemistries within these broader classifications. For example, lithium-ion batteries can be lithium polymer, lithium iron phosphate (LiFePO4) and lithium air (amongst others).

Rechargeable lithium batteries are in most of the devices that you use on a regular or even daily basis (the device you are reading this on may even be powered by one).

This means they can be found in, amongst others:

• Smartphones and mobile phones.
• Laptops and tablets.
• E-bikes.
• Power tools.
• Rechargeable children’s toys.
• Electric and hybrid vehicles.

You should be able to tell if a device has a lithium battery by checking the product’s instruction manual, the manufacturer’s website, or contacting them directly.

Yes – a lithium cell is a single unit, and a battery or battery pack is a collection of cells.

The main issue with lithium batteries is their propensity (under certain conditions) to catch fire. They are also very difficult to extinguish once they’re alight, making it particularly dangerous if this occurs on an aircraft or vehicle.

There are many scenarios where you or your customers might need to ship batteries. Selling electronic devices online, for example, or having customers return damaged or defective items for refunds are just two examples.

Another is that if you are part of a supply chain, where you are handling items or components that use batteries of this type.

The short answer is yes, but due to strict rules and legislation, you must be sure you are doing so correctly.

No, you cannot send lithium batteries on their own via domestic or international post.

You can only send lithium batteries in the UK or international post when they’re contained in a device (although some services allow for exceptions). It is also possible to send lithium batteries in the UK when they’re sent with their device (although again, there are some exceptions).

When shipping abroad, lithium batteries must remain inside their associated device. It is not possible to ship lithium batteries separately. Plus, when shipping lithium batteries abroad, you must also check the specific rules in the country that you are shipping to.

A lithium cell is defined as a single enclosed electrochemical unit consisting of a positive and negative electrode that exhibits a voltage differential across the two terminals.

A lithium battery is two or more cells electrically connected. A single-cell battery is considered a cell, not a battery, for the Dangerous Goods Regulations.

Units commonly referred to as “battery packs” or “power banks”, which have the primary function of providing power to another piece of equipment, are treated as batteries for the set out regulations.

A button cell battery, also commonly referred to as a “coin” cell, is a small, round cell whose overall height is less than its diameter.

Understanding these definitions is essential, as different transport modes and battery types fall under specific international rules. The following explanations provide a quick reference to help you navigate the requirements for compliant and safe lithium battery shipments.

Packaged batteries or cells must be separated to prevent short circuits and terminal damage. They must be packed in a strong, rigid outer packaging unless contained within equipment, and the battery is afforded equivalent protection by the equipment in which it is included.

Yes, or at least work with someone who is trained and understands all of the necessary regulations. This could, for example, be the supplier of your lithium battery packaging or cases.

There are several tasks you should undertake.

Firstly, if the item(s) being shipped are faulty, you must ensure the damage has not affected the batteries. You must also check that the batteries have not been identified as faulty or defective (check with the manufacturer) or that there are no visible signs of damage or bulging.

Effectively, when shipping any lithium batteries, you should ensure you adhere to the Dangerous Goods Regulations.

You should use good quality and sturdy packaging, ensuring that the devices/batteries can’t move or become “activated” during transportation, ensure the appropriate labelling is in place (depending on how many items you are sending) and stick to the limits for the number of items you can send in a single pack.

It is essential to prevent cells/batteries from coming into contact with conductive materials (e.g., metal) as this may cause a short circuit (and increase the risk of fire). It is also wise to protect against activation (the device becoming live), covering the switch or ensuring the packaging does not interfere with it.

For any package containing lithium batteries, you must include the relevant handling label and a Transport Document.

You can only send up to two lithium batteries (or four lithium cells) in a single package.

You are not allowed to ship faulty lithium batteries via couriers or post. Please speak with a qualified expert if you need to do this.

Your batteries should have watt-hour ratings marked on them. Section I Lithium-ion batteries manufactured after 31^st December 2011 and Section IB and Section II Lithium-ion batteries manufactured after 1^st January 2009 are required to be marked with the watt-hour rating.

If you can’t see the marking or are unsure of your lithium-ion battery’s watt-hour rating, contact the manufacturer.

There are several ways to help prevent batteries from short-circuiting. This includes packing each battery or each battery-powered device in fully enclosed inner packaging made of non-conductive material.

Separating or packing batteries to prevent contact with other batteries, devices, or conductive materials (e.g., metal) should also be done, as should ensuring that exposed terminals or connectors are protected with non-conductive caps, non-conductive tape, or other appropriate means.

The following exterior packaging has been determined as safe for use in shipping lithium batteries (if regulations are adhered to):

• Drums: Steel, aluminium, plywood, fibre, plastic, and other metals.
• Jerri cans: Steel, aluminium, and plastic.
• Boxes: Steel, aluminium, wood, plywood, reconstituted wood, fibreboard, plastic, and other metals.

Zarges aluminium cases with tailored foam inserts are amongst the safest performing methods for transporting all forms and conditions of lithium batteries.

Not necessarily (although strongly advisable); if it’s not impact-resistant, then the outer packaging must not be used as the sole means of protecting the battery terminals from damage or short-circuiting.

Batteries should be securely cushioned and packed to prevent shifting, which could loosen terminal caps or reorient the terminals, causing short circuits. Inserts are an excellent way to achieve this.

Although rules vary depending on the mode of transport, the majority were set by the IATA (International Air Transport Association) in 2009 following several incidents in which lithium batteries ignited and caused fires on aircraft.

The United Nations has also classified lithium batteries as hazardous goods.

Each package must be labelled with a completed lithium battery marking. This includes:

• UN number
• Telephone number for more information on the shipment and its contents.
• Minimum dimensions: 120x110mm.
• The information on the lithium battery handling label must be in English.
• An accurate printed translation can supplement text in another language.

Please see the example below:

Devices such as radio frequency identification (RFID) tags, watches, and temperature loggers, which are not capable of generating a dangerous amount of heat, may be transported when intentionally active.

When active, these devices must meet defined electromagnetic radiation standards to ensure that their operation does not interfere with aircraft systems. The devices must also not emit disturbing signals (such as buzzing alarms, strobe lights, etc.) during transportation.

The label/marking is not required for:

• Packages containing only button cell batteries installed inside equipment (including circuit boards).
• Consignments of two packages or fewer, where each package contains no more than four cells.
• Two batteries are installed in the equipment.

If one package contains a combination of lithium batteries within equipment and lithium batteries packed with equipment that meets limits for lithium cells or batteries of Section II, the following requirements will also apply:

• The shipper must ensure that all applicable parts of both packing instructions are met.
• The total weight of lithium batteries contained in any package must not exceed 5kg.
• The words “lithium-ion batteries, in compliance with Section II of PI966” or “lithium metal batteries, in compliance with Section II of PI969” must appear on the documentation.

Packages that individually comply with the requirements may be consolidated into an overpack.

An overpack is an exterior box or case containing the smaller individual packages. This must be marked with the word “over pack” and labelled with the lithium battery handling label unless the labels on the particular packages inside the over pack remain visible (or the label is not required).

In addition to standard regulations, numerous air operators impose ad hoc restrictions on the carriage of lithium batteries. It is wise to check with your transport provider.

Transport requirements for both road and sea freight are similar, but generally less restrictive.

Any shipment compliant for air transport can also be transported by road or sea (although this doesn’t work the other way around).

To find out specific rules and regulations for shipping lithium batteries via sea freight or by road, please view the IMO (International Maritime Organisation), ADR (The European Agreement Concerning the International Carriage of Dangerous Goods by Road) documents and guidelines.

If a package is too small to display the full-size lithium mark, the mark dimensions may be reduced to 105mm wide and 74mm high. The design specifications must remain the same, however.

The telephone number should be of a person with specific knowledge of shipments. It is not for the purpose of obtaining immediate emergency-response guidance (meaning it does not need to be monitored throughout the shipment). It is acceptable to monitor the number during the company’s regular business hours.

It is also acceptable to use an emergency response, 24-hour phone number on the lithium battery mark.

No, IATA does not require a material safety data sheet (MSDS or SDS) or the UN 38.3 test data report as part of the necessary documentation requirements when offering lithium batteries for transport.

The completed package containing batteries, as prepared for transport in accordance with the relevant packing instruction, must be capable of withstanding the 1.2m drop test. The “package” in this instance includes both the inner packaging containing batteries and the equipment; the equipment must comply with the packing instructions, which require it to pass the 1.2m drop test.

Zarges aluminium battery boxes have been drop tested to ensure they comply with this requirement.

Lithium batteries, identified by the manufacturer as being defective for safety reasons, or that have been damaged, that have the potential of producing a dangerous evolution of heat, fire, or short circuit, are forbidden for transport by air (e.g., those being returned to the manufacturer for safety reasons).

This also applies to lithium cells or batteries installed inside equipment such as mobile phones, laptops, or tablets, where the devices are subject to recall due to safety concerns about the lithium cell or battery.

Please speak with your transport provider for shipping defective batteries via other means (road or sea).

No, for lithium-ion batteries shipped in accordance with Section IA or Section IB of PI965, which must be on a shipper’s declaration. The shipper’s declaration includes a certification statement, “I declare that all of the applicable air transport requirements have been met”.

By signing the shipper’s declaration, the shipper is making a legal statement that all applicable provisions of the Dangerous Goods Regulations have been complied with, including that the lithium-ion batteries are at no more than 30% SoC.

By walking through common situations, like packaging multiple devices, using lithium battery marks, managing spares, handling defective items, or shipping temperature-monitoring equipment, it illustrates how regulatory requirements work in practice across different modes of transport. Use these scenarios as a quick reference to ensure your shipments remain safe and fully compliant.

For packages of single devices like these, no lithium battery mark would be required, since up to four of these single-cell batteries can be placed in a box without applying the lithium battery mark to the outer box. If five devices are in a single shipping package, a lithium battery mark on the shipping package is required.

Yes, the mark may bear all applicable UN numbers, e.g., UN3091, UN3481, to identify that the package contains lithium metal batteries packed with, or contained in equipment and lithium-ion batteries packed with, or contained in equipment.

Yes, the 12 batteries reflect two spares for each of the four power tools in the outer package, plus one spare for the device.

The quantity limits shown in the packing instructions refer to a maximum (net) weight of lithium batteries in each package. Provided each package remains within the limit specified in the packing instruction, there are no quantity limits specified for an overpack.

Batteries with other defects (e.g., LEDs not showing charge, incorrect model number on the label, or batteries not holding enough charge) can be shipped (including by air), subject to meeting the relevant provisions.

Yes, all provisions of the Dangerous Goods Regulations apply to shipments of Section IB batteries, except those listed in Section IB. Therefore, dangerous goods training as indicated in Subsection 1.5 of the Dangerous Goods Regulations is required.

Devices such as laptops or tablets that are returned may not have a defective battery, may not meet the customer’s needs, may be defective themselves (but not the battery), etc. In these situations, all forms of transport (including air) would be permitted. However, the battery or equipment manufacturer should be contacted to determine the appropriate shipping method.

Yes, all applicable provisions for lithium batteries must be followed by the shipper of such devices, including limitations for devices that are “active” (on) during transport.

Note: The perishable cargo regulations (PCR) also apply to such a shipment.

Safely shipping lithium batteries is a complex subject, with potentially dire consequences if you get it wrong (hence the long list of frequently asked questions).

Please note, however, that every application and scenario will be slightly different. If you are in any doubt, speak with the battery manufacturer and/or your chosen transport provider for further clarification.

For more information on lithium battery packaging, please contact our team of packaging experts.