Lithium-based batteries have become the preferred power source for many portable and high-performance electronic products because they provide high energy density while maintaining a relatively lightweight form factor. Whether using lithium-ion, lithium iron phosphate, or other lithium-based chemistries, these batteries support applications that require compact size, longer runtime, and higher power output.
However, lithium batteries also present unique safety considerations. Battery packs require a battery management system to monitor State of Charge (SoC), State of Health (SoH), temperature, and other operating conditions. If a battery experiences a short circuit or thermal runaway event, the result may be fire, explosion, or other hazardous conditions.
Because of these risks, lithium batteries are subject to transportation regulations that govern how they are classified, packaged, labeled, and shipped. These requirements apply to commercial shipments as well as many situations involving personal transport of lithium-powered devices.
Regulatory Organizations Involved in Lithium Battery Shipping
Lithium battery transportation is governed by multiple organizations depending on the mode of transportation and the regions involved.
Air Transportation
For batteries transported by air, international standards established by the United Nations Economic Commission for Europe (UNECE) and the International Air Transport Association (IATA) apply. Lithium batteries transported by air are assigned specific UN classifications and must comply with applicable air transport regulations.
Maritime Transportation
For shipments traveling by sea, the International Maritime Organization (IMO) establishes requirements through the International Maritime Dangerous Goods (IMDG) Code.
Ground Transportation
Ground transportation requirements vary by country.
In the United States, lithium battery transportation regulations are established by the Department of Transportation (DOT). In Europe, transportation requirements are defined by the European Commission (EC). Regional and local carriers may also impose additional requirements for lithium battery shipments.
Hazardous Materials Classification
Lithium battery chemistries are generally classified under Hazard Class 9: Miscellaneous Hazardous Materials when traveling internationally by ground or sea.
Lithium Battery Shipping Requirements
Certain lithium battery shipments transported by air may also fall under the Class 9 designation depending on battery type, battery size, packaging configuration, and other classification factors.
Understanding whether a shipment qualifies as Class 9 is an important step because classification affects labeling, documentation, packaging, and transportation options.
Factors Used to Classify Lithium Battery Shipments
Lithium battery classifications are based on several characteristics.
For air transportation, regulatory requirements consider:
- The amount of lithium metal contained within the battery.
- The watt-hour rating of the battery.
- How the battery is packaged for shipment.
- Whether the battery contains lithium metal or lithium-ion chemistry.
Classification is further determined by whether:
- Batteries are shipped loose without accompanying equipment.
- Batteries are packed with equipment.
- Batteries are installed inside equipment.
- Lithium-ion batteries are shipped loose with a State of Charge (SoC) of 30% or less.
When Lithium Batteries May Not Require Class 9 Labeling
Not all lithium battery shipments fall under Class 9 hazardous materials requirements.
Lithium metal batteries packed with equipment or installed inside equipment may avoid the Class 9 designation when:
- Batteries contain less than 2 grams of lithium.
- Individual cells contain less than 1 gram of lithium.
Similarly, lithium-ion batteries packed with equipment or installed in equipment may avoid Class 9 classification when:
- Individual cells are rated at 20Wh or less.
- Batteries are rated at 100Wh or less.
Classification should always be evaluated based on the battery specifications and packaging configuration being used for shipment.
Shipping Limitations for Loose Lithium Metal Batteries
Loose lithium metal batteries are subject to some of the strictest transportation requirements. These batteries:
- Cannot be transported in passenger aircraft cargo holds.
- Require Class 9 hazardous materials labels.
- Require Cargo Aircraft Only labels.
For batteries containing 2 grams or more of lithium and cells containing 1 gram or more of lithium:
- Maximum package weight: 35 kg.
- No limit on the number of packages.
For cells and batteries below those lithium-content thresholds:
- Maximum package weight: 2.5 kg.
- No package limit for high-volume shipments.
For low-volume shipments:
- A 2.5 kg package limit applies to cells containing 0.3 grams or less of lithium.
- Shipments are limited to a maximum of 8 cells or 2 batteries when those thresholds are exceeded.
- Only one package may be shipped at one time.
Shipping Limitations for Lithium Metal Batteries Packed With Equipment
When lithium metal batteries are packaged with equipment, requirements change based on the transportation method.
For passenger aircraft:
- Maximum package weight: 5 kg.
- Applies regardless of lithium content.
For cargo aircraft:
- Maximum package weight: 35 kg for batteries containing more than 2 grams of lithium or cells containing more than 1 gram of lithium.
- No limit on the number of packages.
Shipping Limitations for Lithium Metal Batteries Installed Inside Equipment
Lithium metal batteries installed within devices or equipment are also subject to weight restrictions.
For passenger aircraft:
- Maximum package weight: 5 kg.
- Applies regardless of lithium content.
For cargo aircraft:
- Maximum package weight: 35 kg when cells contain more than 1 gram of lithium or batteries contain more than 2 grams of lithium.
- No limit on the number of packages.
Shipping Limitations for Loose Lithium-Ion Batteries
Loose lithium-ion batteries cannot be transported on passenger aircraft. They must be shipped with a charge level below 30% and require Class 9 hazardous materials labeling.
Weight limits are determined by watt-hour ratings.
Cells Equal To or Greater Than 20Wh or Batteries Equal To or Greater Than 200Wh
- Maximum package weight: 35 kg.
Cells Less Than or Equal To 20Wh or Batteries Less Than or Equal To 200Wh (High-Volume Shipping)
- Maximum package weight: 10 kg.
Cells Less Than or Equal To 20Wh or Batteries Less Than or Equal To 200Wh (Low-Volume Shipping)
- Maximum package weight: 5 kg for individual cells below 2.7Wh.
- Cells above 2.7Wh are limited to 8 cells or 2 batteries.
- Only one package may be shipped.
Lithium-Ion Batteries Packed With or Installed Inside Equipment
Separate requirements apply when lithium-ion batteries are shipped with equipment or installed within equipment.
For cells rated at 20Wh or greater and batteries rated at 200Wh or greater:
- Class 9 hazardous materials labeling is required.
- Passenger aircraft shipments are limited to 5 kg per package.
- Cargo aircraft shipments are limited to 35 kg per package.
For cells rated at 20Wh or less and batteries rated at 200Wh or less:
- Maximum package weight is 5 kg for both passenger and cargo aircraft.
- No package quantity limitations.
Compliance Considerations Beyond Shipping Limits
Shipping lithium batteries involves more than meeting weight and packaging restrictions.
Organizations must also ensure that shipments comply with applicable documentation, labeling, classification, and transportation requirements established by relevant regulatory agencies and carriers. Requirements may vary depending on the destination, shipping method, battery chemistry, battery capacity, and how the batteries are packaged.
For personnel responsible for preparing lithium battery shipments, proper training is an important part of compliance.
Summary
Understanding all the regulations and standards associated with shipping lithium batteries can ensure that your products reach customers as you fill orders. When it comes to certifications, only the IATA requires it for workers who will manage, handle, and apply shipping labels to lithium battery packages.
You may obtain other certifications from regulatory bodies based on where the intended market lies as consumers will know that the batteries have undergone testing and meet compliance standards. Specialized certifications may also be required based on the industry that will use the products. Typically, other battery chemistries do not require such regulations or certifications as they are not under the same restrictions.
Key Takeaways
- Lithium Batteries Are Strictly Regulated Due to Safety Risks: Because lithium batteries can catch fire or explode during thermal runaway, international and domestic shipping regulations are in place to manage these risks across air, land, and sea.
- Multiple Regulatory Bodies Set the Rules: Shipping standards are governed by organizations such as IATA (air), IMO (sea), UNECE, DOT (U.S. land), and the EC (Europe), with batteries classified under UN codes and Hazard Class 9 when applicable.
- Classification Depends on Battery Type, Size, and Packaging: Whether a lithium battery is loose, packed with equipment, or contained inside equipment impacts how it is classified and what shipping restrictions apply, including watt-hour rating and lithium content.
- Passenger Aircraft Face Tighter Restrictions: Loose lithium batteries and higher-capacity lithium-ion packs are often banned from passenger aircraft and must be labeled as Class 9 hazardous materials, with strict weight and packaging limits.
- Proper Training and Labeling Are Mandatory: IATA requires certification for personnel handling lithium battery shipments, and compliance with labeling, packaging, and documentation is essential to avoid shipping delays or regulatory violations.
