How to ship batteries safely

Updated 17 七月 2025

Battery logistics is a high-stakes, high-regulations business. One misstep, and you’re looking at potential fines, cargo fires, or even full-blown transport bans. Why? Because batteries are classified as dangerous goods due to fire and explosion risk. That means stricter packaging, labelling, documentation, and carrier approvals.

This guide explains everything you need to know to stay compliant and avoid costly delays – from battery classifications to mode-specific rules and best practices for shipping safely.

Why is shipping batteries challenging?

Shipping batteries – especially lithium batteries – presents serious safety risks if not handled properly. These batteries are prone to fire, leakage, or short circuits, which is why they are classified as dangerous goods (DG) and are subject to strict transport regulations.

Improper packaging or declaration can lead to:

Thermal runway, fires, or explosions in transit
Cargo damage from leaking or overheating batteries
Injury to cargo handlers or emergency responders
Fines, delays, or rejected shipments due to non-compliance
Emergency landings or vessel diversions in extreme cases

An image of a hazard label for Class 9 dangerous goods.

Most lithium batteries are classified as Class 9 dangerous goods but the exact handling requirements depend on:

Battery chemistry (e.g., lithium-ion vs lithium-metal)
Battery condition (new, used, or damaged)
Whether they are shipped alone, installed in equipment, (e.g., smartphone with built-in battery), or with equipment (e.g., cordless drill with battery in separate compartment)

Other battery types – like lead-acid, nickel-metal hydride (NiMH), and dry cell batteries — may fall under different categories, but all require proper classification, documentation, and packaging to move legally and safely.

How are batteries classified for shipping?

Different battery types come with different risks, which affect how they're packed, labeled, and shipped.

Here’s a quick guide to the most common battery types and their shipping classifications:

Battery type	UN number(s)	Examples	Risk class (DG)	Notes
Battery type Lithium-ion (Li-ion)	UN number(s) UN 3480 / UN 3481	Examples Smartphones, laptops, e-bikes, EVs	Risk class (DG) Class 9	Notes High energy density. Max 30% charge for air transport. Damaged/recalled units require special handling.
Battery type Lithium-metal	UN number(s) UN 3090 / UN 3091	Examples Watches, medical implants, GPS devices	Risk class (DG) Class 9	Notes Stricter rules than Li-ion. Heavily restricted by air, especially when shipped loose.
Battery type Lead-acid	UN number(s) UN 2794 / UN 2800	Examples Car batteries, backup power systems	Risk class (DG) Class 8	Notes Corrosive and spillable. Must be kept upright and often requiring venting.
Battery type Nickel-cadmium (NiCd)	UN number(s) UN 2795	Examples Industrial tools, aviation equipment	Risk class (DG) Class 8	Notes Corrosive. Must follow Clas 8 packing rules if contain free-flowing electrolyte.
Battery type Nickel-metal hydride (NiMH)	UN number(s) UN 3496	Examples Power tools, consumer electronics	Risk class (DG) Not DG*	Notes Generally not regulated, but some carriers or local rules may apply.
Battery type Dry cell (alkaline)	UN number(s) Not regulated**	Examples AA/AAA batteries, household electronics	Risk class (DG) Not DG	Notes Usually not regulated unless damaged, leaking, or shipped in bulk.

Notes:

DG = Dangerous Goods
* NiMH batteries are generally exempt under international law, but always check with your carrier, especially for air shipments.
** Damaged or defective batteries (any type) are always treated as high-risk and require special approvals, packaging, and labeling.

How to prepare batteries for shipping

Here's how to ensure your battery shipments are compliant, secure, and ready for transport:

Identify and classify the battery type

Start by understanding what you're shipping. You’ll need to know:

Battery chemistry (e.g. Li-ion, lithium metal)
Specifications (UN number(s), Watt-hour rating)
How it’s packed (loose, with equipment, or installed)
Condition (new, used, damaged, or defective)

This determines which regulations apply and how the battery must be handled and declared.

Use compliant packaging

Proper packaging helps prevent leaks, short circuits, and fires. Ensure that:

Batteries are placed in inner packaging (like fiberboard, plastic, or blister packs)
There's enough cushioning to prevent movement
Everything is placed in a strong outer box (fiberboard, wooden, or metal)
Terminals are protected with caps or insulation to avoid short circuits
Packages are kept upright and away from heat sources

Damaged or leaking batteries need UN-certified packaging with absorbent material and leak-proof seals.

Label and mark shipment correctly

To ensure clear labelling, include:

The correct UN number (e.g. UN3480 for Li-ion)
Proper shipping name (e.g. Lithium-ion batteries)
A hazard label (Class 9 for lithium batteries, or Class 8 for some other types)
A lithium battery handling label (if required)
Orientation arrows (when applicable)
A 24/7 emergency response number

Use laminated or weatherproof labels, and make sure labels are not placed on removable or temporary packaging like shrink wrap.

Prepare accurate documentation

Depending on the battery type and transport mode, your shipment may require:

Dangerous Goods Declaration (DGD)
Material Safety Data Sheet (MSDS) or Safety Data Sheet (SDS)
Battery Test Summary (proving UN 38.3 compliance for Li-ion/Li-metal)
Emergency response guide (how to handle fire or damage)
Transport booking document with UN number and description
Pilot notification (for air shipments)
Packaging certificates (for UN-certified materials)
Government exemptions or special approvals (for damaged or defective batteries)

Tip: Always check the latest requirements for your destination and transport mode as rules can vary by region and carrier.

What transport modes can be used to ship batteries?

Batteries can be shipped by different modes of transportation, but the rules change with each mode:

Mode	Governing regulation	Notes
Mode Air	Governing regulation IATA DGR and IATA Lithium Battery Shipping Regulations (LBSR)	Notes Most restrictive; state of charge (SOC) ≤ 30%. No damaged units.
Mode Ocean	Governing regulation IMDG Code (International Maritime DG Code)	Notes Allows large volumes with proper declaration, labelling, and packing compliance.
Mode Road	Governing regulation ADR (Europe), DOT regulations (US)	Notes Country-specific limits on weight, quantity, segregation. Route planning critical.
Mode Rail	Governing regulation RID (Europe), FRA (US), regional equivalents elsewhere	Notes Regional variations in limits and documentation. Mirror road regulations.

Not all battery types can be shipped by air. For example, lithium-ion batteries over a specific Watt-hour rating must be shipped by sea or road. Also, some airlines may have carrier-specific rules more stringent than IATA’s baseline.

Shipping lithium batteries by air vs ocean: What changes?

As you’ll see below, different rules apply depending on whether you are shipping batteries by air or sea:

Requirement	Air (IATA)	Ocean (IMDG )
Requirement SOC limit	Air (IATA) ≤ 30% (for standalone batteries)	Ocean (IMDG ) No SOC requirement
Requirement Damaged batteries	Air (IATA) Prohibited	Ocean (IMDG ) Allowed with special packaging
Requirement Packaging	Air (IATA) Strict inner + outer	Ocean (IMDG ) Inner + outer, less restrictive
Requirement Labels	Air (IATA) Mandatory + size specifications	Ocean (IMDG ) Mandatory but flexible format
Requirement Documentation	Air (IATA) Extensive	Ocean (IMDG ) Moderate

Best practices to ship batteries safely

To stay compliant and avoid disruptions, follow these industry best practices:

Train your team: Anyone handling battery shipments must be DG-trained. Have an emergency response plan and Standard Operating Procedures (SOPs) at all facilities and in transit.
Segregate and label correctly: Use certified battery packaging and accurate documentation. Keep batteries away from flammable goods and heat sources.
No damaged batteries: Never ship swollen, leaking, or recalled batteries without proper clearances or approvals.
Review before every shipment: Regulations evolve; check IATA/IMDG updates.

Need help shipping batteries safely?

Handling battery shipments requires more than standard logistics. It’s a high-risk, high-compliance task that demands precision at every step – from correct classification and certified packaging to compliant documentation and safe, mode-specific transport.

Whether you’re moving new electric vehicles by ocean, Power up your battery supply chain with Maersk Air Cargo, or storing components in between, we simplify complex battery logistics. Our teams handle dangerous goods with care, ensure documentation aligns with global DG regulations, and support certified packaging, customs compliance, and safe storage.

With expertise spanning ocean, air, and inland modes – as well as specialised services like reverse logistics and regulatory support – we help ensure your battery shipments move safely and smoothly from origin to destination.

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