All about transporting lithium batteries and IoT devices

If you’re planning on shipping your batteries or battery-powered IoT devices by air, sea, rail or road then there are a number of rules that must be adhered to.

Lithium batteries are classed as dangerous goods, only for the purpose of transportation. With billions of rechargeable and nonrechargeable lithium cells and batteries powering most of the world’s consumer and industrial electronic devices, shipping them to the customer through vast global logistics chains is often an overlooked subject.

Safety requirements have led to a tightening of air transport regulations when transporting lithium batteries. Failing to follow these rules could lead to serious consequences, including significant fines. With that in mind, it’s essential for you - and your chosen carrier – to take the time to ensure that during shipping, these lithium batteries are appropriately declared, labeled, packaged, and stored.

With that in mind, here we explore the things you need to know before shipping your lithium batteries or lithium battery powered devices.

Choosing your shipping company

Not all shipping companies can ship lithium batteries.

So first and foremost, when shipping lithium batteries by road, sea, rail or air, you should choose a reputable carrier that has guidelines in place for shipping these items, together with trained personnel who understand how lithium batteries work and how to handle them safely. FedEx, USPS, UPS or DHL can do the job but there are also other commercial carriers. Just make sure they have a hazmat contract or a pre-approval for your specific type of lithium batteries and follow the UN/IATA/ICAO/Dangerous Goods regulations.

Since 2016, the transport of lithium-ion batteries aboard passenger aircraft in bulk shipments has been prohibited so you’ll have to find the relevant carrier. This prohibition is not applicable to batteries packed with, or contained in equipment.

Note: There are specific cargo-only carrying aircraft following the ICAO regulations, which allow lithium cells and batteries to shipped in bulk.

You are required to provide the carrier with the appropriate documentation. Most reputable companies will provide you with a Shipping Guide stating their specific requirements for lithium-ion and lithium metal battery shipments according to the chosen mode of transport.

Don’t forget, most freight nowadays is multi-modal: the shipment could start its journey by road, followed by air and then by road or rail. Packing your shipment for air transport is the surest way to ensure it will comply with the necessary requirements all the way.

Labeling your package - understand the classifications and shipping descriptions

Additionally, the United Nations Committee of Experts on the Transport of Dangerous Goods have classified dangerous goods under specific UN Numbers and “proper shipping names”.

There are six possible shipping names (and labels) with corresponding UN numbers for lithium battery shipments based upon the type and how the package is configured:

You will need to indicate the sizing of the batteries on your battery product label. Lithium-ion batteries are sized by power rating in Watthours (Wh) per cell and Watt-hours per battery. Normally, the power is indicated on the battery itself, as this is now mandatory (older batteries manufactured before 1st January 2009 may lack this labeling). Make sure you confirm the information with your manufacturer as it might not be indicated on the cell.

For Saft batteries, the information is indicated in the data sheet available for each one of our batteries. Click here to download your specific product documentation.

Proving your credentials: The UN 38.3 test summary

As of 1st January 2020, producers and subsequent distributors of cells or batteries have had to provide a Test Summary Report (or TSR), as specified in the UN Manual of Tests and Criteria, before lithium cells/batteries can be transported. This is a series of eight tests simulating safety in transport and environmental transport conditions such as: pressure, temperature, shock, vibration, impact, altitude, etc. The test summary report includes a summary of the cell or batteries test results. Without this test summary report being made available to the transport logistics chain, the shipping of lithium cells and batteries is prohibited.

So, it’s important when choosing your battery manufacturer to remember that only cells and batteries manufactured under a quality management program may be suitable for transport.

Complete the UN 38.3 test summary report online

Packing your shipment

The packing of lithium batteries or IoT devices is usually handled by the entity that ships the package as they are typically the signatories on the shipping declaration, which requires specific information depending on a number of parameters.

The detailed requirements for any given lithium battery shipment may vary significantly depending on the battery type, size, quantity, configuration, weight, transporter, destination, and mode of transportation. It also depends on whether you are shipping batteries or cells only, cells or batteries packed with equipment (separately in the same package) or cells or batteries contained in equipment.

The “Recommendations on the Transport of Dangerous Goods Model Regulations, Twenty-first revised edition (ST/SG/AC.10/1/Rev.21)” is the base reference document underlying the regulatory structure for all transport modes.

The document provides detailed guidance for classification, packaging and many other details, specific to various cases of transport for all classifications of dangerous goods including Lithium rechargeable and non-rechargeable cells and batteries – for example;

1. Small quantities of Li metal and Li-ion cells and batteries.

a. Special provision, Chapter 3.3, 188 (a), (b) etc.

2. Lithium cells and batteries when installed in equipment.

a. Special Provision Chapter 3.3, 188 (e), etc.

Care must be taken to understand any additional requirements imposed by the different modes of transport. Additional requirements and restrictions may be imposed by the various carriers, many of which address Lithium battery shipments.

Packaging may require official testing to prove it will protect its contents during transport when exposed to dropping, stacking, moisture etc., before being allowed to transport Lithium cells and batteries. Fortunately, this type of qualified packaging is readily available and pre-qualified from suppliers globally.

In summary

Nowadays, billions of batteries are shipped annually. Lithium battery accidents in transport are very rare, thanks to the regulations and high standards for air, road, sea and rail shipping.

At first glance, it may appear a daunting task to meet all of these regulations, but on the contrary, it is not difficult to ship your batteries or battery-powered devices, you just need to know what you are doing before you start.

That starts with making sure that your chosen carrier is up to date with the regulations and follows the revisions that are being published on a regular basis.

Then, just follow the instructions around how to properly label and pack your shipment.

If you need any advice on how to transport your Saft batteries, we can provide the expert insight you need and set you on the path to safely preparing your shipments in compliance with international transport regulations.

Get in touch at energizeIoT@saftbatteries.com.