How to ship lithium batteries.
Lithium batteries power everything from phones to power tools — and because a damaged cell can catch fire, they are regulated dangerous goods. Shipping them safely means getting the classification, packaging, marking and paperwork right. Here is how, framed honestly, with pointers to the rules that actually govern it.
What are lithium batteries?
"Lithium battery" covers two distinct families, and the difference matters for how you ship them. Both store a lot of energy in a small space, which is exactly why they are so useful — and why a failure can be serious.
Lithium-ion (rechargeable)
Lithium-ion cells are the rechargeable batteries in phones, laptops, power tools, e-bikes and electric vehicles. For shipping, their energy is measured in watt-hours (Wh), and that rating — along with whether they travel alone or inside equipment — decides which packing rules apply. They ship under UN 3480 (alone) or UN 3481 (in or with equipment).
Lithium-metal (primary)
Lithium-metal batteries are typically non-rechargeable primary cells — the coin cells and long-life batteries in watches, medical devices, sensors and cameras. Their key measure is lithium content in grams. They ship under UN 3090 (alone) or UN 3091 (in or with equipment). Because the two chemistries behave differently, they are regulated separately.
Why they are regulated
The reason for all the rules is straightforward: lithium batteries pack a large amount of energy into a small space, and a cell that is damaged, short-circuited, overcharged or defective can overheat and enter thermal runaway — releasing heat and, in the worst case, catching fire. That is a serious hazard in the enclosed environment of a truck or an aircraft cargo hold, which is why regulators classify these batteries as dangerous goods and set specific requirements for how they are packed, marked and documented. The rules are not bureaucracy for its own sake; they are the accumulated response to real incidents, and getting them right keeps your shipment — and everyone handling it — safe.
Ten tips for shipping lithium batteries safely
A working checklist for preparing a compliant, safe lithium battery shipment. Verify each against the current rules for your battery and mode.
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Identify the battery type and UN number
Classification is the first and most important step. Lithium-ion cells and batteries ship under UN 3480 (alone) or UN 3481 (in or packed with equipment); lithium-metal ships under UN 3090 or UN 3091. Watt-hour rating (for lithium-ion) and lithium content (for lithium-metal) determine which packing rules apply.
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Manage the state of charge
Lithium-ion batteries are generally required to be shipped at a reduced state of charge — commonly not more than 30% — to lower the energy available if a cell fails. Confirm the current requirement for your mode and battery before you ship.
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Prevent short circuits
Insulate or cap the terminals and pack cells so they cannot contact each other or conductive materials. A short circuit is the most common trigger for a thermal event, so terminal protection is non-negotiable.
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Protect against physical damage
Cushion each battery and immobilize it inside the package so it cannot shift, be crushed, or be punctured in transit. Damaged cells are a fire risk, so the packaging must survive normal handling.
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Use strong, compliant outer packaging
Ship in rigid outer packaging that meets the applicable packing instruction. Many lithium shipments require specification (UN-rated) packaging; the right box, inner packaging and cushioning are defined by the rules for your battery and quantity.
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Mark and label correctly
Apply the required lithium battery mark and, where the rules call for it, the Class 9 lithium battery hazard label. Correct marking tells every handler what is inside and how to respond — and missing or wrong marks are a leading cause of rejected shipments.
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Handle damaged, defective or recalled batteries separately
Batteries that are damaged, defective or recalled are subject to much stricter rules and are often forbidden in normal transport. Never ship them as ordinary lithium batteries; they require special handling and, in many cases, specialized packaging.
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Complete accurate documentation
Prepare the shipping papers your mode requires, with the correct UN number, proper shipping name and quantities. Accurate documentation is both a legal requirement and what keeps the shipment moving instead of held.
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Train the people who pack and ship
The regulations require that people who prepare hazardous shipments be trained. Make sure whoever classifies, packs, marks and documents lithium batteries understands the current requirements for your mode.
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Partner with an experienced carrier or broker
Lithium battery rules are detailed and change over time. Working with a partner who ships regulated goods every day is the most reliable way to get the classification, packaging, marking and paperwork right the first time.
The role of a freight brokerage
Regulated goods are exactly where an experienced partner earns its keep. Lithium battery rules are detailed, mode-specific and revised regularly — the kind of thing that is a full-time job to keep current. A freight brokerage that moves regulated freight every day brings that fluency to your shipment.
We help match your battery to the right UN number and packing instruction, route it with carriers equipped to handle Class 9 freight, and make sure the marking, labeling and documentation line up with the requirements for your mode. As a TSA Indirect Air Carrier, RS Group is set up for the compliance side of regulated shipping — so a lithium shipment moves cleanly instead of getting held or refused.
Lithium battery shipping questions
The questions shippers ask most about moving lithium batteries — answered plainly.
Are lithium batteries considered hazardous materials?
Yes. Lithium-ion and lithium-metal batteries are classified as dangerous goods (hazardous materials), generally under hazard Class 9, because a damaged or defective cell can overheat and catch fire. That classification is why they carry specific packaging, marking, labeling and documentation requirements across ground and air transport.
What are UN 3480, 3481, 3090 and 3091?
They are the UN identification numbers for lithium batteries. UN 3480 is lithium-ion batteries shipped by themselves; UN 3481 is lithium-ion batteries contained in or packed with equipment. UN 3090 is lithium-metal batteries alone; UN 3091 is lithium-metal batteries in or with equipment. The right number depends on the battery chemistry and how it is packed.
Where do I find the current lithium battery shipping rules?
The governing rules include the U.S. DOT hazardous materials regulations (49 CFR, administered by PHMSA) for ground transport and the IATA Dangerous Goods Regulations for air, which reflect the ICAO Technical Instructions. These are updated regularly. Always work from the current published edition for your mode, and treat this article as general background rather than compliance guidance.
Need to ship lithium batteries or hazmat?
Regulated freight is our territory. Tell us what you're shipping and we'll help you get it classified, packed, marked and moving — compliantly.