Shipping Batteries Safely: Complete Lithium Battery Guide

Lithium batteries power most of our electronics but are classified as hazardous materials. Here's how to ship them safely and legally.

Why Batteries Are Regulated

Lithium batteries can:

• Overheat: Thermal runaway risk
• Catch fire: Difficult to extinguish
• Explode: In extreme conditions
• Be damaged in transit: External damage increases risk

Types of Lithium Batteries

Lithium-Ion (Li-ion)

• Rechargeable: Yes
• Common in: Phones, laptops, power tools
• UN Number: UN3481 (with equipment)
• Risk level: Moderate

Lithium Metal

• Rechargeable: No
• Common in: Watches, cameras, medical devices
• UN Number: UN3091 (with equipment)
• Risk level: Higher

Shipping Configurations

Section I vs Section II

Packing Configurations

Carrier Policies

USPS

UPS

FedEx

Watt-Hour Calculation

Calculate watt-hours to determine section:

Watt-hours (Wh) = Voltage (V) × Amp-hours (Ah)
Example:
3.7V × 2.6Ah = 9.62Wh (Section II)

Common Product Watt-Hours

Required Labels and Marks

Section II Labels

Required markings:

Lithium battery mark:

• Black border
• Pictogram of battery
• UN number
• Phone number

Package orientation arrows (if liquid in battery)

UN specification packaging (for standalone)

Documentation

Packaging Requirements

Section II Packaging

• Strong outer packaging
• Protect terminals from short circuit
• Prevent movement within package
• Each cell/battery in inner packaging

Terminal Protection Methods

International Battery Shipping

IATA Restrictions

International air shipping has additional limits:

Country-Specific Restrictions

Compliance Checklist

Before shipping batteries:

• [ ] Calculate watt-hours per battery
• [ ] Determine section (I or II)
• [ ] Check carrier acceptance
• [ ] Select appropriate packaging
• [ ] Protect all terminals
• [ ] Apply required marks/labels
• [ ] Complete documentation
• [ ] Train shippers (if required)

Common Violations

Violation 1: Wrong Classification

Consequence: Package rejection, fines up to $500,000 Prevention: Calculate Wh accurately

Violation 2: Missing Labels

Consequence: Shipment delay, carrier penalty Prevention: Apply proper lithium battery mark

Violation 3: Unprotected Terminals

Consequence: Safety incident, liability Prevention: Tape or package properly

atoship Battery Shipping

Ship batteries compliantly:

Battery type classifier: Determine requirements

Watt-hour calculator: Accurate section classification

Label generator: Correct lithium battery marks

Carrier filter: Show battery-accepting options

Documentation: Required forms

Conclusion

Lithium battery shipping requires understanding regulations, proper packaging, and correct documentation. Use atoship to navigate carrier requirements, generate compliant labels, and find battery-accepting shipping options at discounted rates.