GWP Protective Lithium Ion Shipping Guide

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Meet all UN regulations Source cases and foam Custom designed foam
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for the safe shipment of inserts from Search
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inserts with calculated
lithium batteries to enhance performance levels of protection
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Lithium Battery Packaging Guide.

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Important information when shipping dangerous goods

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Please see below for a quick guide to the contents of this guide.

Introduction
Why protection of your high value equipment and products is crucial to your business success
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01 What are Lithium Batteries? Environment Specialist corrugated

An explanation of the types of Lithium battery, and why they are regulated
Exclusives Stock Reduction

02 Dangerous Goods Classification
A full table showing all forms of dangerous goods
Foam Packaging Waterproof cases
03 UN Regulations Fulfilment Wesbsite
Rules and applicable regulations for safely shipping lithium batteries Why GWP
04 Labelling Required
Rules on labelling and documentation
05 Ground (Road) Shipping Requirements
Specific regulations when shipping lithium batteries via road / rail networks (ADR)
06 Air Freight Requirements
Rules, legislation and exceptions when shipping via air (IATA)
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© Copyright 2006-2018 GWP Group
Registered Office: GWP Group Limited, Unit 20 Chelworth Park, Cricklade, Wiltshire SN6 6HE | Registered in England and Wales No.05459368

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Regulations for safe shipping of hazardous

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Many people assume it is safe to ship lithium ion batteries without much thought to
shipping method or packaging. But this is not theDistributors
case. Sheet material
It is simply dangerous and potentially illegal to put them into any old box and send them,
with a number of laws and regulations already in place to ensure the safety of those
transporting them. Emails SPA
play when trying to ascertain whatSpecialist corrugated

Environment
In fact, there are a number of factors that come into
packaging and method you should use when transporting lithium ion batteries. These are
UN3480, UN 3481 and UN3090),SSI Schaefer
ESD Foam
governed by a number of UN regulations (specifically
as well as rules set out by various transport bodies (including the IATA – International Air
Transport Association). Exclusives Stock Reduction
Foam
Looking at the list of criteria and influencing factors can be in credibly daunting, whichUnique Benefits
is why this guide - alongside the articles you can find on the gwp.co.uk website - aims to
Foam Packaging
provide you with a solid understanding of what is required.
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Fulfilment Wesbsite
Saying that, if you have any specific questions then you may find this list of FAQs useful, or
alternatively speak with an adviser at GWP who will be happy to help.
Why GWP
We hope you find it useful and informative, but should you have any further questions then
please do not hesitate to contact a member of our team.
Richard Coombes
General Manager | GWP Protective
Key points this guide covers:
> What are the UN regulations

> Where and when do they apply
> Labelling and packaging requirements
> Specific rules for transit by ground
> IATA regulations for air cargo

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Cases 01722 416 440 Packaging products

protective@gwp.co.uk
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01: What AreContact

Lithium
Us
Batteries?
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What are Lithium Batteries? Custom cases Rigid plastic products Wh
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...and why are they so dangerous Damage Sample cases Quote
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As the name would suggest, lithium batteries are used as a power source for a range Large quantities of batteries pose
Corstat
of products, appearing in everything from electricDistributors
cars to power tools and mobile a significant safety risk, which
Sheet material
Resources
phones. is particularly acute when being
shipped by air. A relatively small
Costs
But moving beyond the obvious, lithium batteries are commonly split into 2 differing Returnable
incident can lead to an uncontrollable
categories – lithium metal batteries and lithium ion batteries.
Emails SPA fire. As a result, lithium batteries are
considered hazardous materials and
Custom cases
non rechargeable, and contain Specialist corrugated
Environment
Starting with lithium metal batteries, these are usually Rigid plastic products
must be handled accordingly.
metallic lithium (hence the name). They typically have a higher “energy density” than
similar non rechargeable batteries, which means ESD are widely used to power items SSI Schaefer
theyFoam
such as calculators, hearing aids, pacemakers and wrist-watches (basically anything
Damage
Exclusives
where you wouldn’t expect to charge or replace the batteries that often). Stock Reduction Sample cases
Foamdo not contain metallic lithium, Unique Benefits

Lithium ion batteries are the newer technology. They
Design
but retain the high energy density of lithium metal batteries but with the added Search
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benefit of being rechargeable. Although they are considered more stable and safer
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than lithium metal batteries, they still pose a significant risk.
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Fulfilment Wesbsite
Sheet material
Why GWP
Problems with Lithium
Put simply, lithium batteries can be extremely dangerous – meaning they are
technically classified as hazardous goods. In fact, a number of unexplained aircraft
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disasters have been attributed to lithium batteries catching on fire during flights SPA
These fires are usually attributed to the batteries short circuiting – something
Environment
that can be solved simply with better, more robust packaging that is tailored to the Specialist corrugated
products they are carrying (such as the Zarges aluminium battery packaging cases).
ESD Foam
Lithium batteries can also be prone to “thermal runaway”. What this basically means
SSI Schaefer
is that if the internal circuitry is compromised, an increase in internal temperature
can occur. At a certain temperature, the battery cells begin to vent hot gasses, in turn
increasing the temperature in neighbouring cells. Ultimately, this will lead to ignition
– and fire.
As such, large quantities of batteries pose a significant safety risk, which is

Foam
particularly acute when being shipped by air. A relatively small incident can lead to an Unique Benefits
uncontrollable fire.
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Why GWP

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02: Dangerous Goods Corriplast
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Dangerous Goods Classification

Table highlighting all forms of dangerous

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Please use the table below for an overview of all types of hazardous goods

Class Labels Description Examples
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Airbags, seatbelt pre-tensioners, fireworks
Class 1 Environment
Explosives Specialist(party
corrugated
poppers), ammunition, flares, fuses,
explosive sounding devices
2.1 Flammable Gas Oxygen, Butane, Propane, Co2 fire
Class 2 2.2 Non-flammable, non-toxic gas
Exclusives extinguishers, air conditioning refrigerant
Stock Reduction
2.3 Toxic Gas gas, aerosols, calibration gasses,
Petrol, diesel, solvents, paints, paint & paint
Class 3 Flammable Liquids related material, formaldehyde solution,
sealers, Kerosene, perfume
4.1 Flammable Solids

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4.2 Substances Liable to spontaneous Wet cotton, metal powders, swarfs, rags
Class 4 combustion contaminated with flammable liquids,
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4.3 Substances in contact with water emit activated Carbon, Sodium
flammable gasses
5.1 Oxidizing substances Calcium chlorate aqueous solution,

Class 5
5.2 Organic Peroxides organic peroxide substances.
Arsenics, pesticides, Isocyanates, Phenols,

6.1 Toxic Substances
Class 6 clinical waste, medical waste, infectious
6.2 Infectious Substances
substances affecting humans or animals,
Radioactive material fissile, uranium

Class 7 Radioactive Material
hexaflouride
Acids & Alkali’s, batteries wet filled with

Class 8 Corrosive
acid / alkali.
Life saving devices Lithium batteries,

Class 9 Miscellaneous dangerous goods environmentally hazardous substances,
Asbestos, electrical capacitors, PCB’s.

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In Transit...
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Whether you are experiencing unacceptable levels of damage
finding shipping costs excessiveDesign
in transit, Markets or simply don’t know Search
which protective case is best for your business, we can help!
Request aNews Distributors

complimentary, no obligation quote or audit of your
Sheet m
existing solution by speaking with one of our engineers today.
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Mon - Fri 8.30 - 17.00 Free advice and quotes
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Protection ESD Foam SSI Sch
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Quote Foam Unique
Resources Foam Packaging Waterp
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Rigid plastic products Why GW
Or read more
Sample cases at www.gwp.co.uk/protective
Search

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03: UN Regulations. Corriplast
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Uni
Classifications & Legislation.

Guide to United Nations regulations

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The shipping of lithium batteries are effectively covered by 4 pieces of UN legislation, although there are numerous specifics within these
which can inﬂuence the exact processes and materials you need to consider to ensureSheet
Distributors safe material
shipping (or at least minimise the risk as far as is
possible). The specific UN regulations covering the shipment of these batteries are as follows:
UN Regulation Batteries Covered
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UN 3090 Lithium metal batteries (shipped by themselves)

UN 3480 Lithium ion batteries (shipped by themselves) or inside equipment or packed separately with equipment
UN 3091 Lithium metal batteries contained in equipment or packed with equipment
UN 3481 Lithium ion batteries contained in equipment or packed with equipment
Requirements for Compliance: Foam Packaging Waterproof cases
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The following table gives an overview of the UN packaging requirements for Lithium batteries.
Why GWP
Item Individually With Equipment In Equipment
Cell content ≤1g of lithium metal or lithium alloy / ≤20Wh rating
Battery content ≤2g of lithium metal / ≤100Wh rating
Cells and batteries shall be packed in inner packaging that Protection against damage and short
completely enclose the cell or battery, protection against short circuits, no conductive materials,
Packaging
circuits, no conductive materials, strong outer packaging that is prevention of accidental activation,
able to withstand a 1.2m drop test strong outer packaging.
Lithium handling label only required if:

Labelling Lithium metal batteries packed with equipment More than 4 cells per package or
More than 2 batteries per package
Contains lithium
Documentation
Is flammable
(only required
Shall be handled with care
when package is
In case of damage, special procedures shall be followed
labelled)
Telephone number for additional information
Package limit 30 kg Not limited


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04: Labelling. Corriplast
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Shipping Labels & Documentation.

Requirements for labelling of packs

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The below labels must be used when shipping Lithium batteries - although the rules vary depending on the number of batteries, their watt
ratings or their (combined) weight. Distributors Sheet material

Fully Excepted Shipments
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Lithium ion (rechargeable) batteries rated at 100-watt hours or less, and lithium metal batteries with two (2) grams or less of lithium
Environment
content, are fully-excepted items. Rating parameters Specialistiscorrugated
increase slightly if the mode of transport limited to highway or rail only. Additional
exceptions apply to individual cells.
Fully-excepted items require only a lithium battery mark that displays the UN number(s), as well as a telephone number which is commonly a
24/7 emergency-response number. Exclusives Stock Reduction
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Why GWP
Fully Regulated Shipments
But regulations tighten for lithium batteries that exceed the exception limits. At that point, the package becomes a fully-regulated shipment
and requires additional documentation, including:
> Class 9 Hazard label

> Shipping papers
> 24/7 emergency contact number


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04: Labelling (continued). Corriplast
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Explanation of Case Marking.

Requirements for labelling of Zarges battery boxes

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The below diagram explains the labelling that you will see on any UN compliant lithikum battery cases.
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Why GWP
A Serial Number
B Packaging type and material. 4B = case made from aluminium. 50B = large container made from aluminium (volume >450 litres)
C Packaging group and gross weight: X102 = VPGR. I, II and III gross weight 102 kg
D Material type: S = solid material or internal packaging without hydraulic internal pressure testing
E Year of manufacture
F Country in which approval was granted
G UN symbol for packaging
H Licensing institution: BAM = Federal Office for Material Research and Testing
I Approval Number: 8311 = Approval No. 8311 issued by BAM
J Abbreviation of manufacturer or testing centre: = Zarges GmbH


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05: Shipping Via Ground. Corriplast
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Uni
ADR Regulations. Custom cases Rigid plastic products Wh
European Agreement Concerning the International CarriageSample

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cases Goods by Road
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If your lithium-ion batteries are being transported by lorry for transport within Europe, you must ensure that you comply with all of the
requirements as outlined in the ADR 2017 manual. This is effectively the European Agreement
Distributors that governs the shipping of lithium batteries
Sheet material
by road / ground (and indeed that of any dangerous goods).
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ADR Packaging Requirements:
The following table gives an overview of the packaging requirements as set out by the ADR
Excepted / Limited Qty. Small Qty. Loads Full ADR Load

> Good quality combination Packaging > Specific

Foam UN Approved Packaging Unique Benefits
> Specific UN Approved Packaging / Tanks
> Compatible with the substance (combination or single)
> Specific Marking and Labelling
> Basic Labelling LQ / EQ label Foam
> Some prescribed max qty per inner and Waterproof cases
Packaging
> Prescribed max qty per inner and outer
> Prescribed max qty per inner and outer packaging’s or single packaging.
packaging or single packaging.
outer packaging Fulfilment
> Specific Marking and Labelling Wesbsite
Why GWP
ADR Transport / Operational:
The following table provides the requirements from a transport / operational perspective
Excepted / Limited Qty. Small Qty. Loads Full ADR Load
> Basic Trained Driver > ADR Trained and Licensed Driver
> Transport document > Placarded and marked vehicle
> Basic Trained Driver
> Specified max small quantity per > Specified additional number of fire extinguishers
> Transport document
transport vehicle & safety equipment
> Carry Unlimited > 8t placarded vehicle
> 1 x 2kg powder fire extinguisher > Handling and Stowage / filling tank requirements
> 1 x 2kg powder fire extinguisher
> Handling and stowage requirements & Supervision
> Handling and stowage requirements
> Any suitable vehicle can carry > Approved vehicle construction type
> Any suitable vehicle can carry
> Supervision where specified > DG Documentation carried on vehicle +
> Any torch non sparking Instructions in writing


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06: Shipping Via Air. Corriplast
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Uni
IATA Regulations. Custom cases Rigid plastic products Wh
International Air Transit Association

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When transporting lithium-ion batteries via air, the Dangerous Good Regulations (DGR) must be reviewed and met. These regulations are
governed by the International Air Transport Association (IATA) and the International Civil
Distributors SheetAviation Organization (ICAO).
material

Lithium Ion Batteries
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All cells and batteries must be tested in accordance with

the UN Manual of Tests and Criteria Part III Subsection
38.3 (DGR 3.9.2.6)

Passed UN? No Redesign

Yes
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Why GWP
Lithium Ion Batteries Lithium Ion Batteries (limited Lithium Ion Batteries
Contained in Equipment to a maximum of 30% SoC) Packed With Equipment
Cells >20 Wh; and Cells ≤20 Wh; and Cells > 20 Wh; and Cells ≤ 20 Wh; and Cells ≤20 Wh; and Cells > 20 Wh; and Cells ≤ 20 Wh; and
Batteries > 100 Batteries ≤100 Wh Batteries > 100 Wh Batteries ≤100 Wh Batteries ≤100 Wh Batteries > 100Wh Batteries ≤100 Wh
Wh
UN3481 UN3480 UN3480 UN3480 UN3481 UN3481
UN3481 PI 967 Section II PI 965 PI 965 PI: 965 PI 966 PI 966
PI 967 Section I *IMP: ELI Section IA Section IB Section II Section I Section II
IMP: RLI IMP: RBI IMP: RBI IMP: ELI IMP: RLI IMP: ELI
Limit per package:
Limit per package: Pax A/C = 5 kg Limit per package: NOTE: Use “IB” if package (not more than 1 Limit per package: Limit per package:
exceeds Section II Limits
Pax A/C = 5 kg CAO = 5 kg Pax A/C = Forbidden or more than 1 package. package) Pax A/C = 5 kg Pax A/C = 5 kg
CAO = 35 kg CAO = 35 kg CAO = 35 kg CAO = 5 kg
Limit per package: Limit per package:
Pax A/C = Forbidden ≤ 2.7 Wh = 2.5kg; or
CAO = 10 kg cells > 2.7 Wh ≤ 20Wh
= 8 cells; or
batteries > 2.7 Wh
≤ 100 Wh = 2
batteries
Pax A/C = Forbidden


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06: Shipping Via Air. Corriplast
Corrugated Boxes
Quality
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Exclusives
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Sto
Uni
IATA Regulations. Custom cases Rigid plastic products Wh
International Air Transit Association

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Design Search
When transporting lithium-ion batteries via air, the Dangerous Good Regulations (DGR) must be reviewed and met. These regulations are
governed by the International Air Transport Association (IATA) and the International Civil
Distributors SheetAviation Organization (ICAO).
material

Lithium Metal Batteries
Emails SPA
All cells and batteries must be tested in accordance with

the UN Manual of Tests and Criteria Part III Subsection
38.3 (DGR 3.9.2.6)

Passed UN? No Redesign

Yes
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Why GWP
Lithium Metal Batteries Lithium Metal Batteries Lithium Metal Batteries
Contained in Equipment Packed With Equipment
Cells >1 g; and Cells ≤ 1 g; and Cells >1 g; and Cells ≤ 1 g; and Cells ≤1 g; and Cells >1 g; and Cells ≤ 1 g; and
Batteries > 2 g Batteries ≤ 2 g Batteries > 2 g Batteries ≤ 2 g Batteries ≤ 2 g Batteries > 2 g Batteries ≤ 2 g
UN3091 UN3091 UN3090 UN3090 UN3090 UN3091 UN3091

PI 970 PI 970 PI 968 PI 968 PI 968 PI 969 PI 969
Section I Section II * Section IA Section IB Section II Section I Section II
IMP: RLM IMP: ELM IMP: RBM IMP: RBM IMP: ELM IMP: RLM IMP: ELM
Limit per package: Limit per package: Limit per package: NOTE: “IB” must be used if Limit per package: Limit per package: Limit per package:
package exceeds Section
Pax A/C = 5 kg Pax A/C = 5 kg Pax A/C = Forbidden II limits and more than (not more than 1 Pax A/C = 5 kg Pax A/C = 5 kg
1 package
CAO = 35 kg CAO = 5 kg CAO = 35 kg package) CAO = 35 kg CAO = 5 kg
Lithium metal content
Limit per package:
≤ 0.3g = 2.5 kg; or
Pax A/C = forbidden
cells > 0.3 g ≤ 1 g
CAO = 2.5 kg
= 8 cells; or
batteries > 0.3 g ≤ 2 g
= 2 batteries
Forbidden on PAX
aircraft


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GWP Protective is a UK designer and manufacturer of custom protective cases, with
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particular expertise in engineered foam inserts. With over 25 years experience, a dedicated
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design team and modern POS
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from precisely engineered
protection for your products that eliminates transit damage and the associated costs. Stock Reduction
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The wider GWP Group can also help with any other packaging requirement you may have.
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Cases Packaging products Efficiency Sin

01722 416 440 protective@gwp.co.uk

Contact Us POS / Retail Environment Spe

Correx products Protection ESD Foam SSI

About About Corstat GuidesGuides Resources Aluminium cases

Costs Returnable Fulfilment We

Environment Specialist corrugated

Costs Costs Returnable

Protection Compatibility Design

Cases Packaging products Efficiency Sin

01722 416 440 protective@gwp.co.uk

Contact Us POS / Retail Environment Spe

Correx products Protection ESD Foam SSI

Corstat Resources Foam Packaging Wa

Costs Returnable Fulfilment We

Lithium Battery Packaging Guide.

Important information when shipping dangerous goods

Distributors Sheet material

01 What are Lithium Batteries? Environment Specialist corrugated

ESD Foam SSI Schaefer

Exclusives Stock Reduction

03 UN Regulations Fulfilment Wesbsite

Rules on labelling and documentation

05 Ground (Road) Shipping Requirements

06 Air Freight Requirements

Rules, legislation and exceptions when shipping via air (IATA)

TEL: 01722 416 440 WEB: www.gwp.co.uk/protective EMAIL: protective@gwp.co.uk

Cases Packaging products Efficiency Sin

01722 416 440 protective@gwp.co.uk

Contact Us POS / Retail Environment Spe

Correx products Protection ESD Foam SSI

Corstat Resources Foam Packaging Wa

Costs Returnable Fulfilment We

Lithium Batteries. Custom cases Rigid plastic products Wh

Regulations for safe shipping of hazardous

play when trying to ascertain whatSpecialist corrugated

Key points this guide covers:

> What are the UN regulations

TEL: 01722 416 440 WEB: www.gwp.co.uk/protective EMAIL: protective@gwp.co.uk

Cases Packaging products Efficiency Sin

Cases 01722 416 440 Packaging products

Contact Us POS / Retail Environment Spe

01: What AreContact

Costs Returnable Fulfilment We

Foamdo not contain metallic lithium, Unique Benefits

As such, large quantities of batteries pose a significant safety risk, which is

Foam Packaging Waterproof cases

Cases Packaging products Efficiency Sin

01722 416 440 protective@gwp.co.uk

Contact Us POS / Retail Environment Spe

Correx products Protection ESD Foam SSI

02: Dangerous Goods Corriplast

Corstat Resources Foam Packaging Wa

Costs Returnable Fulfilment We

Dangerous Goods Classification

Table highlighting all forms of dangerous

Efficiency Single Source

4.1 Flammable Solids

5.1 Oxidizing substances Calcium chlorate aqueous solution,

Arsenics, pesticides, Isocyanates, Phenols,

Radioactive material fissile, uranium

Acids & Alkali’s, batteries wet filled with