#1 Guide for Commercial Shipping of Lithium Batteries

#1 Guide for Commercial Shipping of Lithium Batteries
 

Every day, there are millions of tons of materials being shipped from one part of the world to the other. There are some products out there that you definitely know require extra safety precautions, while there are other items in existence that you previously thought were harmless yet turn out to be harmful under the right conditions.

Shipping cargo to harborOne of such items is lithium batteries. You might not know this, but lithium batteries have always been a safety concern for those who have experience with the shipment and receiving of these batteries. They only recently got negative attention in the mainstream media last year due to the incident where Samsung Galaxy Note7 and hoverboards were recalled in large numbers due to the fact that they would spontaneously burst into flames.

What makes lithium batteries simultaneously useful yet dangerous is that they possess a large amount of energy in a small amount of space. Often, there will be a short circuit due to overheating, device misuse, or a software malfunction that will eventually lead to a series of chain reactions where the temperature of the chemicals in the battery start to rise. Experts cite overcharging as one of the primary reasons why these events happen.

While these events are rather rare in their frequency, they happen enough that the International Air Transport Association (IATA) has created strict guidelines regarding the shipment of lithium batteries so that shippers can stay in line within the safety regulations. For those who are unfamiliar with the regulations or are unsure on how to navigate through them, the 2017 Lithium Battery Shipping Guidelines (4th Edition) is a wise investment that will get you up to speed.

This guide will attempt to cover the most important points regarding the commercial shipping of lithium batteries and will serve as an overview that is applicable to either the person shipping or receiving the batteries. With that being said, specific details regarding certain aspects of shipping lithium batteries can be found in the previously linked book.

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The Basics


When in doubt, you should treat batteries as hazardous materialsThe first thing to remember is the default position regarding the status of lithium batteries. They are classified as hazardous materials, with exceptions for smaller-sized batteries. When in doubt, you should treat them as such or consult the rulebook to see if the exceptions apply to your personal circumstances.

The next thing to point out is that the rules that apply to you depend on the method of shipping used to transport the batteries, along with the type of lithium battery you are shipping. Lithium metal and lithium ion are the two types of batteries that you need to be concerned about. Although they serve the same purpose and function in a very similar manner, there are some subtle differences that will determine how you are going to pack them.

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Lithium Ion (Li-on) vs. Lithium Metal


The ion batteries are rechargeable and are commonly found in portable devices such as laptops and smartphones. They are also called “secondary lithium batteries,” so make sure to watch out for that terminology when reading the regulations. It’s a small difference that can make the difference between a smooth shipping process and dealing with an annoying fine.

As for the metal batteries, they are non-rechargeable and are also referred to as “primary lithium batteries” on occasion.

laptop battery charger adapter

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How to Prevent Short Circuiting During Shipping


Smartphone battery swellingAn accidental short circuit during shipping is the #1 safety concern when it comes to the commercial shipping of lithium batteries. If a battery is packed in isolation from its device, it needs to be kept out of contact with metal objectives, other batteries, and surfaces that can conduct electricity.

Non-conductive material should be used as packaging, and it should fully enclose the lithium battery. If there are any terminals that are exposed to the open, they should be covered up with material that does not conduct electricity.

If you can, add some cushioning material so that the batteries will not move around during transportation. Avoid using soft-sided packs such as envelopes to wrap up the battery. This is applicable to both types of lithium batteries.

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Labeling


The labels that will be used for the package containing your lithium battery are dependent on the type of battery being shipped and the manner in which they are packed. If the battery is contained within a piece of equipment, packed alongside a piece of equipment, or packed in isolation, this will need to be specified in the attached documentation and on the package itself. This applies to both types of lithium batteries.

The documentation must also state that the package should be handled with care due to the potential of a fire hazard taking place, that special procedures need to be carried out should the package receive any kind of damage, and that contact info via telephone should be provided for any additional questions or information.

There are two labels that need to be on packages containing lithium batteries

There are two labels that need to be on the package containing the lithium batteries:

The first label is a distinctive handling label (11 cm x 12 cm) that summarizes the documentation, described a moment ago, using visuals. Lithium ion batteries and lithium metal batteries each have their separate labels.

The second label, “Cargo Aircraft Only – Forbidden In Passenger Aircraft” applies to both types of lithium batteries and must also be present on the packaging.

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Regarding Batteries That Have Been Recalled, Are Damaged, or Are Defective


Lithium batteries meeting any of the criteria mentioned in the above subtitle are forbidden from aircraft transportation due to the safety hazard that they bring onto the flight. Postal services, by the nature of the rules, are also forbidden from accepting or shipping these types of batteries.  

If you absolutely need to transfer batteries with these criteria, the U.S. Department of Transportation (DOT) has some guidelines on their official website regarding the safe transportation of recalled lithium batteries.

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Batteries vs. Cells


IATA makes a distinction between a battery and a cell. A cell is defined as a singular electrochemical unit, while a battery is a group of cells electrically connected to one another

and packed into a common housing unit.

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Small, Medium, Large Lithium Cells, & Batteries


Both types of lithium batteries are further classified as small, medium, or large, depending on the amount of lithium content in primary lithium batteries or the equivalent lithium content (ELC) for secondary lithium batteries.

Below is a summary table taken from a Pipeline and Hazardous Material Safety Administration whitepaper that explains this concept in further detail. Note that if these cells/batteries are shipped without equipment, these types must NOT be combined in the same package:

Battery cell category definitions

“Small” lithium batteries need to be covered with strong outer packaging and cushioning, and a divider should be placed between lithium batteries if there is more than one being packed into a box.

Anything that is loose or which has a metal object attached to it should not be in the same box as the lithium batteriesAnything that is loose or which has a metal object attached to it should not be in the same box as the lithium batteries. The batteries need to have passed the tests in the “UN Manual of Tests and Criteria” in order to be eligible for transportation.

Secondary lithium batteries and cells are permitted aboard the aircraft if they are properly identified and packed appropriately, whereas primary lithium batteries are forbidden to be carried as cargo under any circumstance.

The packaging must be appropriately marked, including documentation specifying the contents of the package and emergency procedures to follow if the package gets damaged. Finally, the total package may not exceed 30 kilograms in weight.

“Medium” and “Large” batteries follow the same rules and regulations for transportation by aircraft. The packaging recommendations are the same as for the “small” batteries, and they must also pass the tests in the “UN Manual of Tests and Criteria” in order to be eligible for transportation.

Close up of rechargeable lithium-ion battery for digital camera

The same restrictions on primary and secondary lithium apply as in the case of the “small” batteries, except that secondary lithium batteries carried as cargo cannot exceed 5 kilograms. In addition to the marking and documentation required for “small” lithium batteries, “medium” and “large” lithium batteries must be packaged in UN Specification combination packaging.

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Watt Hours


In addition to being separated on the basis of lithium content, lithium ion batteries are also divided into groups on the basis of their capacity (Watt hour * rating, Wh). DHL Express has a “Lithium Batteries Guidance” document that summarizes this categorization in picture form. If you are interested in reading the document further, every single classification of lithium battery is provided with a comprehensive checklist that ensures all of the packaging and documentation requirements are account for:

Lithium batteries regulationsWhile there are many more nuances, the criteria mentioned in this guide are the most important ones to be mindful of when you are about to commercially ship your lithium batteries. The IATA has provided a 2017 Lithium Battery Guidance Document for public access that will help the first-time worker ensure that the batteries are packed safely and according to law.

In addition to providing an easy-to-read flowchart that will help you classify any lithium battery, there is an extensive FAQ section provided that answers questions about packing lithium batteries according to the rules set out by IATA’s Dangerous Goods Regulations (DGR).

There are UN-tested shipping kits available for purchase that will ensure the safe shipment of all types of lithium batteries and cells. They come with the box itself, along with any cushioning and protective material that you may need to pack the batteries safely. This will help to expedite the process because it will save you time and money that would be wasted on trying to purchase the parts separately and bring them together.

We hope that this informative guide was useful in providing you with the most up-to-date information on the safe and lawful shipping of lithium batteries as dangerous goods. If you would like to see a brief flowchart summary that discusses most of the main points discussed, the United Parcel Service (UPS) has posted a useful PDF that contains a flowchart for each type of battery that helps you decide if you need to ship lithium batteries as dangerous goods or not. Differences may apply, depending on the postal service you are using, but the general concept remains the same.

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