What precautions should be taken when shipping lithium batteries?
Precautions for shipping lithium batteries focus on preventing short circuits, thermal runaway, and regulatory compliance. Batteries must be UN38.3 certified, packed in UN-approved containers at ≤30% state of charge for Li-metal types, and clearly labeled with Class 9 hazard diamonds. Air shipments require specific IATA Dangerous Goods declarations, while ground transport mandates fire-resistant secondary packaging. Pro Tip: Always separate batteries from conductive materials using non-flammable dividers.
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What packaging is required for lithium batteries?
UN-certified packaging is mandatory, using rigid outer shells with 1.2m drop-test compliance. Inner packaging must electrically isolate terminals with caps or tape. For air transport, limit net battery weight to 35kg per package.
Three-layer protection is standard: individual battery insulation, non-conductive inner layers, and crush-resistant outer boxes. Pro Tip: Use vermiculite-filled containers for high-capacity (>100Wh) industrial batteries—the mineral’s thermal resistance adds crucial fire mitigation. For example, a 300Wh e-bike battery shipped internationally requires UN 3481 labeling, 2cm foam cushioning, and “Cargo Aircraft Only” markings if containing lithium-ion cells exceeding 20Wh each.
| Packaging Type | Max Watt-Hours | Marking Code |
|---|---|---|
| PI 965 | 100Wh (cells) | UN3480 |
| PI 966 | 300Wh (packs) | UN3481 |
| PI 968 | 2.5g Li-metal | UN3090 |
How does state of charge affect transport safety?
Shipping lithium-ion batteries at ≤30% charge reduces fire risks by lowering electrolyte reactivity. Li-metal batteries require full discharge (0V) with irreversible protection circuits.
Thermal runway likelihood increases exponentially above 50% SOC due to enhanced ion mobility. Airlines particularly enforce the 30% rule—a partially charged 500Wh battery pack generates 40% less heat during thermal events than fully charged equivalents. But what if emergency shipments need higher charges? Special “Section II” exceptions allow up to 50% SOC with additional fireproof pouches and separate cargo holds. Practical example: Medical device batteries often use Section II provisions, requiring extra documentation and dual-layer ceramic fiber wrapping.
| Battery Type | Max SOC | Special Requirements |
|---|---|---|
| Li-ion (Consumer) | 30% | Terminal protection |
| Li-metal | 0% | Permanent discharge |
| LiFePO4 (Industrial) | 50% | Ceramic separators |
Battery Expert Insight
FAQs
Only via ground transport in UN-approved salvage containers with spill trays. Damaged cells require complete electrolyte neutralization and separate fire compartment storage.
Are prototype batteries subject to different rules?
Yes—prototypes require special EX388 test certificates and must be shipped at ≤10% SOC with double-layer hermetic sealing. Air transport is prohibited without civil aviation authority approval.