Regulations around lithium-ion battery shipping are confusing—but getting it wrong can cost you more than just money.
Shipping small lithium-ion batteries1 requires strict compliance with international air, sea, and ground transport rules, including IATA2, ICAO3, and local government regulations.
Shipping batteries4 isn’t just about boxing and labeling—it’s about protecting people and cargo5. Let’s walk through the rules and how to stay compliant6.
How are lithium-ion batteries classified for shipping?
Confusion often starts with the battery itself—is it a cell? A battery? Part of equipment?
Small lithium-ion batteries are classified based on watt-hour rating (Wh), packaging form (loose, packed with equipment, or installed), and their shipping scenario.
Understanding the classification matters
Small lithium-ion batteries7 (≤100Wh per battery or ≤20Wh per cell) are subject to different shipping rules8 depending on how they're packed9.
| Category | Description | Example |
|---|---|---|
| UN3480 | Battery shipped on its own | Spare power banks |
| UN3481 (with equipment) | Battery packed with but not in equipment | Battery packed beside a camera |
| UN3481 (contained) | Battery installed inside equipment | Battery inside a smartphone |
Knowing the right UN number is the first step in following the correct documentation, labeling, and packaging rules.
Which regulations and authorities govern shipping these batteries?
Many first-timers think FedEx or UPS set the rules—but they’re just enforcers, not the regulators.
Shipping lithium batteries10 is regulated by global and national authorities: IATA11 for air, IMDG12 for sea, and DOT for ground transport (US).
Who you need to follow
The main bodies setting the rules are:
| Organization | Role and Relevance |
|---|---|
| IATA | Air shipping rules, updated yearly |
| ICAO | United Nations standard-setter for international air travel |
| DOT (USA) | Ground/air rules in the US via 49 CFR |
| IMDG | Maritime shipping regulations |
| ADR | Road transport rules in Europe |
Failure to follow even one of these correctly can result in shipment rejections, fines, or worse—fire risks in cargo holds.
What are the labeling and packaging requirements?
Too many shippers forget: packaging isn't just about protection, it's also about communication.
All lithium-ion battery shipments must be packed to prevent short circuits, resist physical damage, and include standardized labels and marks.
What’s required on the outside of the box?
Depending on how the battery is shipped (loose, with equipment, or installed), the package must include:
- Lithium battery handling label (Class 9)
- UN number (UN3480 or UN3481)
- Phone number for emergency response
- “Cargo Aircraft Only” label if applicable
Packaging should also meet drop test and crush resistance standards. Most batteries need to be in strong outer packaging with internal non-conductive cushioning.
| Shipping Form | Required Label | Packaging Notes |
|---|---|---|
| Standalone (UN3480) | Class 9 + CAO label | Strictest, cargo-only aircraft |
| With equipment | Class 9 | Strong outer packaging |
| Installed in device | Class 9 (often exempt) | May be eligible for fewer restrictions |
What documents must be prepared?
Don't let paperwork ruin your shipment—it’s not optional.
A Dangerous Goods Declaration (DGD) and airway bill with specific battery details are required for most lithium-ion battery shipments.
What to include
Here’s a basic checklist of required documents:
- Shipper’s Declaration for Dangerous Goods (if required)
- Air Waybill with correct UN number
- Packaging certificate (for tested pack designs)
- State of charge confirmation (≤30% for air shipments)
- Training records for the person preparing the shipment
Without proper documentation, your batteries won’t ship—and you may lose your shipping account privileges.
What are the quantity and state of charge limits?
Shipping 1 battery is not the same as shipping 100. Also, full batteries aren’t allowed on planes.
Air shipments of small lithium-ion batteries are limited to 5kg per package, and batteries must be at or below 30% state of charge.
Why these rules exist
The 30% SoC limit exists because fully charged lithium batteries are more likely to experience thermal runaway in high-pressure aircraft environments. Here are some key quantity restrictions:
| Mode of Transport | Max Weight/Package13 | SoC Limit14 | Passenger Aircraft Allowed?15 |
|---|---|---|---|
| Air (Cargo Only) | 5 kg | 30% | Yes, with proper labeling |
| Air (Passenger) | Often restricted | 30% | Only for installed batteries |
| Ground (US DOT) | Higher limits | No limit | Yes |
You should always check the latest IATA DGR manual before preparing your shipment—it updates every year.
What are the emergency response and training requirements?
It’s not enough to follow the rules—you also need to be ready if something goes wrong.
Regulators require anyone shipping lithium batteries16 to be trained in hazard recognition, emergency response17, and documentation protocols.
What you need to train and document
- Recognize early signs of battery failure (heat, swelling, smell)
- Know proper use of Class D fire extinguishers (never water!)
- Understand emergency procedures during transit
- Maintain training records for at least 2 years
Even couriers like FedEx and DHL require proof of training before accepting lithium battery shipments, even if labeled correctly.
Conclusion
Shipping small lithium-ion batteries isn’t hard—if you follow the rules, label everything right, and keep training up to date.
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Understanding the regulations for shipping lithium-ion batteries is crucial for compliance and safety in transport. Explore this link for detailed guidelines. ↩
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IATA provides essential guidelines for the safe transport of lithium-ion batteries. This resource will help you understand their role in shipping regulations. ↩
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ICAO sets international standards for air transport safety, including lithium-ion batteries. Learn more about their regulations to ensure compliance. ↩
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Understanding the regulations for shipping batteries is crucial for safety and compliance. Explore this link to ensure you're informed. ↩
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Learn how shipping regulations are designed to protect both individuals and cargo, ensuring safe transport practices. ↩
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Discover best practices for compliance in shipping to avoid penalties and ensure safety in your operations. ↩
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Understanding the shipping rules for lithium-ion batteries is crucial for compliance and safety during transport. ↩
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Exploring shipping regulations helps ensure safe and legal transport of lithium-ion batteries, avoiding potential fines. ↩
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Learning the proper packing methods for lithium-ion batteries can prevent accidents and ensure safe delivery. ↩
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Understanding the regulations for shipping lithium batteries is crucial for compliance and safety in transport. ↩
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Exploring IATA's guidelines can help ensure safe air transport of lithium batteries, minimizing risks. ↩
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Learning about IMDG regulations is essential for safe maritime transport of lithium batteries, protecting the environment and safety. ↩
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Understanding weight limits is crucial for compliance and safety in shipping. Explore this link for detailed guidelines. ↩
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Discover why SoC limits are important for safety and efficiency in transporting goods, especially batteries. ↩
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Learn about the regulations for transporting batteries on passenger aircraft to ensure safe travel and compliance. ↩
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Understanding the regulations for shipping lithium batteries is crucial for compliance and safety in transportation. ↩
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Learning best practices for emergency response can prepare you for potential incidents, ensuring safety and compliance. ↩
