Shipping lithium batteries safely
Lithium batteries are more popular than ever, and despite the restrictions, they can be shipped safely by ground and by air.
Lithium and lithium-ion batteries power a vast range of devices, from smartphones and laptops to power tools and electric vehicles. Their efficiency and reusability have made them part of daily life. Shipping them is another matter: lithium batteries are classified as hazardous materials, and shipping hazardous materials takes careful attention to safety and to the regulations.
At RS Group we have built our freight brokerage expertise around exactly these challenges, so lithium battery shipments move safely, efficiently, and legally. Here is what you need to know.
What are lithium batteries?
There are two main types. Both have high energy density, a long lifespan, and light weight, which is why so many electronics use them.
Lithium metal batteries
Use lithium metal or a lithium compound as the anode. Most are single-use (primary) batteries, found in watches, calculators, cameras, and some medical devices.
Lithium-ion batteries
Are rechargeable and contain no lithium metal. Instead, lithium ions move from the negative electrode to the positive one as the battery discharges, and back again as it charges. These are the batteries in your smartphone, your laptop, and electric cars.
These batteries have changed how we store and use energy, but they carry a risk: if damaged, badly packed, or exposed to high heat, a cell can overheat and ignite, and the heat can spread from cell to cell. This chain reaction, called thermal runaway, is why lithium battery shipments are so tightly regulated.
Which rules apply?
In the United States, the Department of Transportation’s hazardous materials regulations govern lithium batteries on the road, and the International Air Transport Association (IATA) Dangerous Goods Regulations govern them by air. Air rules are generally the stricter of the two. In both, lithium batteries fall under Class 9, miscellaneous dangerous goods, and the requirements depend on the battery’s chemistry, its size (watt-hours for lithium-ion, lithium content for lithium metal), and how it is shipped:
- UN 3480: lithium-ion batteries shipped on their own
- UN 3481: lithium-ion batteries packed with equipment, or contained in it
- UN 3090: lithium metal batteries shipped on their own
- UN 3091: lithium metal batteries packed with equipment, or contained in it
Small cells and batteries. Lithium-ion cells of no more than 20 Wh and batteries of no more than 100 Wh, or lithium metal cells with no more than 1 g of lithium and batteries with no more than 2 g, qualify for reduced requirements, though they still have to be packed and marked correctly. Above those limits, they ship fully regulated as Class 9.
The UN 38.3 test summary. Every lithium cell and battery design must pass the UN 38.3 tests in the UN Manual of Tests and Criteria, and its manufacturer has to make a UN 38.3 test summary available to everyone further down the supply chain. Ask your supplier for it before you ship.
Damaged, defective, or recalled batteries fall under much stricter rules and should never ship as ordinary freight. Requirements are updated regularly, so confirm the current rules for your shipment with your carrier, or with us, before you ship.
Essential tips for safely shipping batteries
Shipping lithium batteries takes a keen eye for detail and a commitment to safety. These ten habits keep shipments compliant and incident-free:
Shield batteries and terminals
Protect every battery and its terminals against short circuits. Cover the terminals with insulating, non-conductive material such as electrical tape or purpose-made protective caps.
Package each battery separately
Place each battery in its own fully enclosed inner package. This protects the terminals and keeps batteries from touching each other or other items.
Avoid overloading packages
Never stack heavy items on packed batteries. Pressure on a battery raises the risk of damage, and damage is where thermal runaway starts.
Keep batteries isolated
Keep batteries away from metal objects that could cause a short circuit, and use enough cushioning to prevent unwanted contact.
Disable devices during transit
Turn off any device with an installed battery before it ships, so it cannot switch on by accident. Where possible, remove the batteries and pack them separately.
Protect device switches
Cover the switches of battery-powered devices with sturdy tape or switch protectors, so they cannot be activated in transit.
Avoid extreme heat
Heat raises the risk of thermal runaway. Store and move lithium batteries in a cool, well-ventilated place.
Check the battery installation
Make sure batteries are not defective and are seated correctly in their devices. A poorly fitted battery can malfunction or short-circuit.
Secure devices in the package
Pad each device so it cannot shift inside the box. Bubble wrap, foam, or other cushioning prevents movement that could damage it or switch it on.
Label the shipment clearly
Make it obvious that the shipment contains lithium batteries. Use the lithium battery mark and any hazard labels and documents your shipment requires, so carriers can handle it with the right precautions.
Shipping lithium batteries?
Tell us what you are shipping and how the batteries are packed, and we will find a carrier that accepts them.
The role of a freight broker in shipping lithium batteries
Lithium battery shipping can be hard to navigate, and that is where a freight broker like RS Group proves its value. A broker links shippers and carriers, using its expertise and network to help shipments, especially hazardous ones, move safely and efficiently and stay compliant.
A brokerage knows the regulations, whether they come from the U.S. Department of Transportation (DOT), the International Air Transport Association (IATA), or another body. That knowledge helps you package and label shipments properly, choose the right carriers, and get the documentation in order.
A broker also has a wide network of reliable carriers. That lets it choose the right one for your batteries on cost, transit time, and experience with hazardous materials, so you save time and money while your shipments stay safe and legal.
How RS Group helps
At RS Group, we are more than a freight broker: we are your partner in shipping lithium batteries. Our team is trained to handle hazardous materials and follows the regulations set by the Department of Transportation.
The responsibilities are split. As the shipper, you classify, package, mark, and label the batteries and certify the shipment on its shipping papers. We offer packaging guidance, check the paperwork, match the load to a carrier approved for hazardous materials, and track it to delivery, whether your batteries move by LTL or by full truckload. We are committed to moving your lithium batteries safely and on time.
Lithium battery shipping FAQ
Can lithium batteries ship by ground?
Yes. Most lithium batteries can ship by ground when they are packed, marked, and documented as the regulations require, and the ground rules are generally less restrictive than the air rules.
Do batteries inside a device still count?
Yes. Batteries contained in equipment are still regulated, under UN 3481 or UN 3091, although the requirements are often lighter than for batteries shipped on their own.
Can I ship damaged or recalled batteries?
Only under special, much stricter rules, and never as ordinary freight. Tell us about the batteries before you book, and we will tell you what the shipment needs.