The UPS guidelines for shipping lithium batteries require proper packaging, documentation, and labeling based on battery type (lithium-ion or lithium metal). Ground shipping is preferred for most consumer batteries, while air transport follows stricter IATA/ICAO rules. Batteries must be protected from short-circuiting and declared with UN3480/UN3090 codes. Non-compliance risks fines or shipment rejection.
How to Prevent Lithium-Ion Battery Fires and Explosions
How Does UPS Classify Lithium Batteries for Shipping?
UPS categorizes lithium batteries as either lithium-ion (rechargeable) or lithium metal (non-rechargeable). Classification depends on watt-hour ratings (≤100 Wh for cells, ≤300 Wh for packages) and lithium content (≤2g for metal batteries). Fully regulated batteries require UN-certified packaging, while smaller “Section II” batteries have simplified requirements. Proper classification determines labeling and documentation needs.
| Battery Type | Watt-Hour Limit | Shipping Category |
|---|---|---|
| Lithium-ion (Cell) | ≤100 Wh | Section II |
| Lithium-ion (Package) | ≤300 Wh | Fully Regulated |
| Lithium Metal | ≤2g Li | Section II |
Recent updates now require separate classification for prototype batteries and those integrated with medical devices. Shippers must account for aggregate lithium content in multi-battery packages, with special calculations required for mixed shipments. UPS provides online tools to help determine proper classification, but recommends verification through certified Dangerous Goods specialists for complex shipments.
What Documentation Is Required for Lithium Battery Shipments?
Mandatory documentation includes a lithium battery shipping document with UN numbers, battery quantities, and emergency contacts. Air shipments require a Shippers Declaration for Dangerous Goods. UPS-specific forms like the Dangerous Goods Contract must be completed. Commercial invoices for international shipments must specify battery chemistry and watt-hour ratings.
| Document Type | Required For | Key Information |
|---|---|---|
| Lithium Battery Document | All shipments | UN number, quantity, emergency phone |
| Shipper’s Declaration | Air transport | Proper shipping name, class |
| Dangerous Goods Contract | UPS shipments | Account information, certification |
New 2024 requirements mandate digital tracking numbers for all hazardous materials documentation. UPS now accepts electronically signed forms through its Dangerous Goods Portal, but paper copies must still accompany physical shipments. Common errors include incomplete emergency contact information and incorrect watt-hour calculations – UPS reports 38% of rejected shipments fail documentation checks for these reasons.
“The 2024 IATA revisions demand new testing protocols for lithium battery shipments. We’re seeing increased use of blockchain for battery pedigree tracking. Smart packaging with embedded sensors now monitors temperature/impact during transit. These innovations help shippers meet evolving safety standards while maintaining supply chain efficiency.” – Logistics Technology Director, Global Battery Shipping Consortium
FAQs
- Can I Ship Lithium Batteries in Original Equipment Packaging?
- Original packaging is only acceptable if UN-certified and undamaged. Most consumer electronics packaging lacks required markings. UPS recommends repackaging in certified materials with proper cushioning and separation.
- How Often Do UPS Lithium Battery Regulations Change?
- Major updates occur annually aligning with IATA/ICAO revisions. Minor changes happen quarterly. Shippers must complete UPS Dangerous Goods training every 14 months to maintain certification.
- Are There Quantity Limits for Small Lithium Batteries?
- Yes. Ground shipments allow up to 8 cells/2 batteries per package. Air shipments restrict to 4 cells/1 battery in Section II quantities. Medical device batteries have separate allowances requiring prior authorization.