How to ship lithium batteries

Lithium batteries power everything from phones to power tools to electric vehicles — and they are classified as dangerous goods because, packed or handled wrong, they can short, overheat and catch fire. That is why shipping them is governed by strict hazmat rules.

This is a general guide to the principles. Always follow the current DOT, IATA and carrier-specific requirements for your exact battery type, and work with a hazmat-trained partner when in doubt.

The rules differ by chemistry, watt-hour rating and whether the battery ships alone or inside a device. Lithium batteries fall under specific UN numbers, and getting the classification right is the foundation of a compliant shipment.

• Lithium-ion batteries (UN 3480) and lithium-ion in/with equipment (UN 3481).
• Lithium-metal batteries (UN 3090) and lithium-metal in/with equipment (UN 3091).
• Watt-hour rating (for lithium-ion) or lithium content (for lithium-metal) determines which packing rules apply.

The core hazard is a short circuit, so packing is built around isolating terminals and stopping movement.

1. Protect the terminals — cap, tape or recess them so they cannot contact metal or another battery.
2. Insulate each battery individually, or use inner packaging that keeps them apart.
3. Use strong, rigid outer packaging that prevents crushing and shifting in transit.
4. Ship only batteries at the state of charge allowed by the applicable regulation.

Hazmat labeling is not optional — it tells every handler what is inside and how to respond. Apply the required lithium battery mark and any hazard class labels for your shipment, and make sure they are visible and durable.

Mislabeled or unlabeled lithium batteries are a common reason a shipment is refused or held, so this step protects your timeline as much as your safety.

A compliant lithium battery shipment travels with the right paperwork: a properly prepared shipping document and, where required, a dangerous goods declaration. The documentation must match the classification, packaging and quantity exactly — a mismatch is treated as a compliance failure.