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Lithium Battery Packaging [Zarges 40582 Case]

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Foam inserts, printing and more

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Tailored pricing on all orders

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More than 25 years experience

Zarges 40582 battery packaging
Fireproof battery box
Lithium Ion battery cases
Zarges battery cases
Zarges battery packaging
UN3480 cases

Fireproof Battery Box

Durable aluminium case for shipping of lithium ion batteries

If you need to ship lithium ion batteries – and with their use in vehicles, tools and consumer devices becoming ever more prevalent – it is important you use correctly specified, UN 3480 approved lithium battery packaging / cases.

The Zarges 40582 fireproof battery box, with specialist GWP manufactured flame resistant Plastazote® polyethylene foam, can meet the required standards for shipping lithium batteries. Read More

Available Colours:

  • No obligation (and no pressure) quotes for any case
  • Impartial advice from UK based experts
  • Competitive pricing and full customisation options


More information on lithium battery packaging requirements

Lithium ion batteries are the power source for ever greater numbers of products, with everything from phones and MP3 players, to batteries for industrial equipment and even electrical cars using them due to their efficiency, cost, and performance.

However, with greater use has come increased reports of safety incidents, due to both the high “densities” of energy they can contain, plus an increased risk of combustion and fires.

To tackle this, a raft of UN and IATA regulations (International Air Transport Association) were introduced, governing what could be shipped, and how (i.e. detailed criteria that the lithium battery packaging must meet).

Zarges 40582 cases / fireproof battery boxes

The Zarges 40582 case – part of the K470 range of aluminium containers – has been designed to satisfy the requirements of this new legislature, absorbing the energy released during a fire.

The interior of the 40582 case is coated with an intumescent material (i.e. one that foams when heated), meaning the cases’ interior swells up to prevent the fire from spreading further.

The other benefit of this is that the temperature of the fireproof battery box exterior does not exceed 100°C, and any smoke is contained within the case as well (preventing alerts being raised).

Zarges 40582 cases have also been tested under the strictest conditions (including UN3480 Class 9 hazardous goods) to ensure all regulatory requirements are met.

Besides this, Zarges lithium battery transportation cases are durable and robust, making the resistant to impact and shock, as well passing the required drop tests for specific types of transit.

This is also in addition to all of the usability benefits inherent in these aluminium cases. This includes easy loading and unloading thanks to the hinged lids, being resealable with the easy to use clasps (which also makes it possible to lock the cases), as well as being easy to transport thanks to their light weight and comfortable handles.

Flame retardant foam and / or Cirrux inserts

However, just as critical to the success of your lithium ion battery packaging / cases, is that of the interior.

As standard, the fireproof battery boxes are supplied with “Cirrux” interior padding, which helps to contain any fires within the specific compartment where it occurs. Similarly to the cases interior coating, the absorbent material filters out solid components from the battery gases. It also allows liquid constituents to condense on the fibres’ surface, preventing any leaked flammable gases from igniting.

This is also an ideal solution if you are transporting lithium batteries by air, road or sea that vary in size and shape (as the Cirrux can be simply wrapped around these different configurations).

If you are shipping high volumes of the same battery however, an alternative option is to use Plastazote® foam inserts and, in particular, fire-retardant grades.

Whilst the principal of containing any fire and ignitable material within a specific compartment of the Zarges 40582 cases interior is the same, there are a number of inherent benefits of this material.

Firstly, the foam can be designed to provide calculated levels of protection from impact, shock and vibration – something which can be critical if transporting damaged or defective batteries.

The foam recessed can also be shaped to exactly match the profile of the batteries to be placed within, further reducing movement (and potential impact) within the case. This also improves usability in terms of packing and retrieval of the batteries.

Key benefits of Zarges 40582 lithium battery packaging

  • Approved for transporting lithium batteries by road, air, and sea
  • Available with Cirrux inserts featuring intumescent (foaming when heated) coating
  • Also supplied with flame resistant foam inserts to also provide enhanced impact protection
  • Standard case with 2 aluminium dividers for up to 3 batteries of up to 500 Wh
  • Easily re-sealable allowing for flexibility
  • Successfully fire tested, with flames contained and not spreading to adjacent batteries
  • Exterior case temperature at the container surface remains below 100°C
  • Tested and meets UN3481, UN3480 and UN3090 Class 9 goods requirements
  • High level of stability and impact resistance due to 3 fully welded aluminium profile frames.
  • Easy to use, with quick loading and unloading
  • Designed for approximately 100 uses / trips when shipping lithium batteries by air / ground


Zarges 40582 technical details

Please use the tables below to see the full specification and sizes of the Zarges 40582 aluminium case.

Internal Sizes

550 mm
550 mm
220 mm

External Sizes

600 mm
600 mm
250 mm

Weight / Capacity

Weight (empty)
11.5 kg
67 l
Min Temp.
Max Temp.


UN3480 / 3481
ADR P908
SV 376


Zarges fireproof battery box in action

For further information on both the Zarges battery boxes, the different insert types as detailed above and general information on packaging lithium batteries for shipment, please watch the short video below.


Common questions on lithium battery packaging

The below covers some of the most commonly asked questions concerning these Zarges battery cases. However, for even more specific questions, please view the detailed lithium battery guide by clicking here.

What products typically include lithium batteries?

Widely used due to their efficiency, cost and low weight, lithium ion batteries are a key part of the drive towards using electric vehicles, as well as in consumer items such as smartphones and power-tools etc. With the automotive industry in particular using increasing numbers of lithium ion batteries due to the demand for hybrid and fully electrical vehicles, their use is also increasing across items such as drills, electrical garden appliances (e.g. strimmers) and various other tools, mainly due to their light weight.

Why do lithium batteries require specialist packaging for transportation?

Shipping damaged Lithium Ion batteries is arguably the hardest challenge manufacturers now face, alongside lithium battery disposal and recycling. Defective or malfunctioning batteries can lead to overheating, or thermal runaways. The worst-case scenario is this resulting in fires, explosions, or gas leaks. Lithium batteries can also go into thermal runaway when coming into contact with external heat sources, such as fire. As such, lithium batteries – and products containing them – are considered hazardous materials or dangerous goods.

What are UN3480 regulations?

UN 3480 comprises the United Nations regulations covering Lithium ion batteries (shipped by themselves). This is closely related to UN 3481, which are the regulations covering Lithium ion batteries contained in equipment or packed separately with a piece of equipment

Will Zarges fireproof battery boxes meet UN regulations?

Any form of lithium battery packaging will require a fairly in-depth design, testing and approval process. However, Zarges cases with customised interiors have passed performance tests related to the package integrity, plus the aluminium Lithium Ion battery cases have UN approval and feature the mandatory UN certification labelling /marks.

Should I use Cirrux or foam inserts my Zarges case?

Both the Cirrux inserts and flame retardant Plastazote® can provide a safe solution for shipping lithium ion batteries. Cirrux tends to be used for lower volumes and when the size and shape of the batteries being shipped my vary, whereas Plastazote® lends itself to higher volumes of a specific item. Foam inserts also provide additional protection from impact and mishandling too.

What are fully excepted shipments?

Lithium ion (effectively rechargeable) batteries that are rated at 100-watt hours or less, and lithium metal batteries with two (2) grams or below of lithium, are often classed as fully excepted items. Any “fully-excepted” items only need the appropriate lithium battery mark, displaying the UN number(s), plus a telephone number providing a 24/7 emergency-response number.

Do other battery types require specialist packaging?

Although lithium-based batteries have been the focus of recent legislation, there are a number of other battery types that require specialist shipping / packaging. For example, Lead acid batteries – and those termed as “spill able” – are classed as dangerous goods under Class 8 (controlled by UN 2749). Besides this, Nickel based batteries, whilst having no specific transit limitations / regulations, require many of the same precautions as listed for lead acid batteries to prevent electrical shorts which could result in fire.

Tailored Pricing / Specification

Ensuring safety for your lithium battery shipments

GWP Protective has nearly 30 years’ experience in providing specialist protective cases with foam inserts for a wide range of industries. And whilst the requirement for safely shipping lithium ion batteries has only become more widespread in recent years, we have experience of producing successful cases for various hazardous materials.

GWP Have also teamed up with a number of leading case brands – including Zarges (manufacturers of UN3481 shipping containers), Peli, Hardigg and SKB, to be able to offer a range of exterior cases that cover virtually every application and requirement.

This is in addition to being trusted by hundreds of companies just like yours to provide customised foam inserts that are calculated to offer the optimum level of protection.

Operating from a well-equipped production facility in Salisbury, Wiltshire, a friendly, knowledgeable team of designers, engineers and support staff will be able to ensure your brief is exceeded regardless of your requirements. Get a free quote or no obligation advice today.

Customisation / Options

Specialist inserts, castors, handles and more

Besides the choice of flame retardant inserts available for Zarges battery cases, there are a number of other accessories that can improve usability too. Please see below for further details.

Cirrux inserts for battery packaging

Cirrux Flame Retardent Inserts

Adaptable flame retardant inserts

Tool control foam

Custom Case Foam Inserts

Flame retardant Plastazote® inserts

Zarges dolly trolley

Heavy Load Dolly Trolley

Dolly trolley to aid movement of cases

Zarges Trolley

Zarges Trolley & Handle

Improve handling of heavy cases

Zarges clip on castors

Clip on Wheels / Castors

Clip on castors with brakes

Alternative Aluminium Cases

Other metal containers available from Zarges

Zarges Euroboxes

Zarges Eurobox Cases

11 Sizes
Custom Options

Zarges K470 aluminium cases

Zarges K470 Containers

26 Sizes
Custom Options

Zarges K470

Aluminium Travel Skips

Kit skips used by pro sports teams

Zarges mitraset cases

Zarges Mitraset 19" Racks

Electro magnetic compatible cases

View All Aluminium Cases

Click here for the full range of options

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    Dan Wellings

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    Richard Coombes

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    Ian Heskins

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    Ensure you are safely and legally shipping Lithium Ion batteries with Zarges 40582 fireproof battery box / lithium battery packaging