Lithium Battery Transport Checklist for Sea and Air Freight

Before You Book: Verify the Regulatory Basis

Shipping lithium batteries by sea or air requires proof that the product has passed specific safety tests. The foundation of any compliant shipment is the UN 38.3 test report. This report demonstrates that the battery, pack, or device withstands drop, thermal, and short-circuit tests without causing fire or injury.

Start your verification by matching the test report to the exact item being shipped. A report for a 18650 cell does not cover a 40-cell pack. A report for a 10 Wh battery does not cover a 100 Wh battery. The UN 38.3 test report must explicitly identify the cell type, chemistry, and nominal voltage. If the report lists a different model number than the one on the shipping label, the shipment is non-compliant.

Next, determine the correct UN number. Most lithium-ion batteries ship as UN 3090 (Lithium ion batteries, containing lithium) or UN 3094 (Lithium metal batteries, containing lithium). Some shipments may qualify as UN 3078 (Lithium ion batteries, packed with or in equipment, containing lithium) or UN 3079 (Lithium metal batteries, packed with or in equipment, containing lithium) if the battery is packed with or in equipment. The UN number determines the required packaging, labeling, and documentation. A mismatch between the UN number on the label and the UN number in the shipping manifest is a common cause of cargo rejection.

Packaging: Check Physical Protection and Integrity

Packaging is the primary barrier against damage during transit. For sea freight, the International Maritime Dangerous Goods (IMDG) Code sets the requirements. For air freight, the International Air Transport Association (IATA) Dangerous Goods Regulations (DGR) apply. Both require packaging that prevents damage, short circuits, and leakage.

Inspect the outer carton or box. It should be made of corrugated cardboard or a stronger material suitable for the weight and size of the shipment. The box must be in good condition. No crushed corners, torn flaps, or water damage. Water damage is a red flag because it can compromise the integrity of the internal packing and the battery cells.

Check the internal packing. Cells and packs must be protected from external damage. This usually means placing each battery in a separate inner box or using foam dividers to prevent contact between cells. If cells can touch each other, the risk of a short circuit increases. The inner boxes must be closed and secured.

For air freight, additional protection against short circuits is required. Terminals must be protected. This can be done by covering terminals with plastic caps, using insulated tape, or placing each cell in a separate plastic bag. The insulation must be rated for the voltage of the battery. A thin layer of paper is not sufficient protection for a 12V battery.

For sea freight, the focus is on securing the load. The outer packaging must be able to withstand the stresses of ocean transport. This includes stacking loads and handling during loading and unloading. If the shipment is a palletized load, check that the pallet is stable and the batteries are strapped down. Loose batteries on a pallet are a safety hazard.

Documentation: Match Every Detail

Shipping documents are the legal record of the shipment. The most critical documents are the Dangerous Goods Declaration (DGD), the Material Safety Data Sheet (MSDS), and the bill of lading or air waybill.

The DGD must be filled out by the shipper. It lists the UN number, proper shipping name, quantity, package type, and number of packages. The quantity must match the number of packages on the pallet or in the container. A discrepancy of even one package can cause a hold.

The MSDS must be current. It provides information on the hazardous properties of the lithium battery, including flammability, reactivity, and storage conditions. The MSDS should be in English or the language of the destination country. If the MSDS is in a different language, a translation may be required.

The bill of lading or air waybill must state the proper shipping name and UN number. For air freight, the air waybill must also state the quantity of packages and the gross weight. The gross weight must match the weight on the package label.

A common mistake is using an old MSDS. If the battery chemistry has changed, or if the packaging has changed, the MSDS must be updated. An old MSDS may not reflect the current safety data. This is a red flag.

Air Cargo Specifics: Watch for Energy Limits

Air freight has stricter limits on lithium battery energy content. The IATA DGR distinguishes between batteries with an energy content below 100 Wh and those with an energy content above 100 Wh. Batteries below 100 Wh can often be shipped in passenger and cargo aircraft without prior approval. Batteries above 100 Wh require prior approval from the operating air carrier.

Check the energy content of each battery. The energy content is calculated by multiplying the nominal voltage by the capacity in ampere-hours (Ah) and dividing by 1000 to get watt-hours (Wh). A 3.7V, 3000 mAh (3 Ah) battery has an energy content of 11.1 Wh. A 12V, 10 Ah battery has an energy content of 120 Wh.

If the battery has an energy content above 100 Wh, it is considered a restricted item. The shipper must obtain prior approval from the air carrier. The approval process can take time. Do not book the shipment until the approval is in hand.

Also check the quantity of batteries. There are limits on the number of batteries that can be shipped per package and per shipment. These limits depend on the energy content. A shipment with too many batteries may exceed the limit and be rejected.

Sea Freight Specifics: Check for Stowage and Markings

Sea freight has different requirements for stowage and markings. The IMDG Code requires that lithium batteries be stowed in a way that prevents them from shifting. They must be secured within the container.

Check the container markings. The container must be marked with the “Lithium Battery” mark if the batteries are packed with or in equipment. The mark must be visible on the outside of the container. If the mark is missing, the container may be rejected.

Also check the “This side up” markings. If the packaging requires the batteries to be kept upright, the container must be marked accordingly. This prevents damage during handling.

For sea freight, the focus is on the stability of the load. A loose load in a container can shift during rough seas. This can damage the batteries and cause a safety incident. The load must be properly secured with dunnage or straps.

Red Flags to Watch For

Before accepting a shipment, look for these red flags. If you see any of them, stop and investigate.

• Missing UN 38.3 test report.
• Test report does not match the battery model.
• Damaged outer packaging.
• Missing or incorrect MSDS.
• Quantity on the DGD does not match the actual number of packages.
• Missing “Lithium Battery” mark on the container.
• Terminals not protected for air freight.
• Energy content above 100 Wh without air carrier approval.
• Load not secured in the container.
• Water damage on the packaging.

Any of these red flags indicate a potential safety or compliance issue. Do not proceed with the shipment until the issue is resolved.

Check Item	Required for Air Freight	Required for Sea Freight	Common Mistake
UN 38.3 Test Report	Yes	Yes	Report for a different model
MSDS	Yes	Yes	Outdated or missing
DGD	Yes	Yes	Quantity mismatch
Terminal Protection	Yes	No	Thin paper used instead of rated insulation
“Lithium Battery” Mark	No	Yes	Mark missing or illegible
Air Carrier Approval	Yes, if >100 Wh	No	Shipment booked before approval
Load Securing	Yes	Yes	Loose pallet load