Even the most frequent and adept traveler may find it hard to prepare for the security line at the airport. What you are and are not required to remove from your bag or your person changes from airport to airport and even from security line to security line, depending on the equipment and personnel available. In the chaos of travel, any consistency is a relief. Luckily, one such area of consistency regards lithium and lithium-ion batteries: which TSA requires to be transported in carry-on baggage vs. checked bags due to fire risks. But what if your lithium batteries aren’t traveling with you commercially? What if you need to ship them? Well, good news: the DOT has very clear and consistent guidelines relating to the shipping of batteries as well.
First and foremost, it is important to understand that lithium batteries are considered a hazardous material (a Class 9 hazardous material, to be precise). This is largely due to their fire risk. Lithium batteries high-energy density and potential for short circuiting make them highly susceptible to thermal runaway – meaning, the battery cell can overheat and trigger a self-sustaining chain reaction, reaching insanely high temperatures incredibly fast, producing hazardous, flammable vapors and, ultimately, igniting or even exploding.
This is obviously a situation to be avoided or mitigated. Thus, we adhere to the requirements and regulations.
There are quite a few rules and regulations surrounding the shipment of lithium batteries and this blogpost is not meant to be a comprehensive guide. Please check the PHMSA and DOT websites for more detailed regulatory requirements.
The basic ‘rules’ call for the batteries and cells to be properly tested, packaged and marked.
For packaging, the DOT requires that lithium batteries and devices containing them are packaged in a way that protects them against short circuiting, shifting within the box, and accidentally activating. Unless the batteries are contained within equipment, the package must be drop tested at 1.2 m in any orientation. If the battery is contained within a device, there must be a way to prevent activation of the device during transportation (this is why your small consumer electronics often arrive in your hands with a pull-tab or tape placed over the switch).
A lithium battery handling mark is required for any package containing more than four lithium cells or two lithium batteries installed in a device. The handling mark must include the appropriate UN identification number as well as a phone number for additional information about the shipment.
The UN identification numbers applicable to lithium battery shipments are as follows:
- UN3480: Loose lithium ion batteries
- UN3481 Lithium-ion batteries “packed with” or “contained in” equipment
- UN3090: Loose Lithium metal batteries
- UN3091: Lithium metal batteries “packed with” or “contained in” equipment
If you suspect that a battery or device is damaged, do not ship it. If you need to, there are much stricter requirements you will need to follow.
How do you know if your battery is damaged? Look for swelling, heat, smell or leaking gas, corrosion, discoloration, cracks, loose wires, previous fire damage or other physical damage and leaks.
Most major carriers offer documentation or even online coursework to help shippers understand and meet all complex regulations. The most recent version of the Department of Transportation regulations for shipping lithium batteries can be found in 49CFR173.185.