UK & International Guide: How to Ship Lithium Batteries

Lithium batteries power almost everything you ship, but they also carry real risk and tight legal controls. The rules change with the battery chemistry and configuration (lithium ion vs lithium metal; in equipment, with equipment, or cells/batteries alone), and with how you move them (air, road, sea, rail). Get any part wrong and you face refused consignments, fines, delays, or worse—a safety incident. Navigating UK requirements alongside international frameworks (CAA/ICAO/IATA, ADR, IMDG, RID) is where many shipments go off-track.

This guide gives you a clear, step‑by‑step route to safe, compliant shipping—whether you’re sending a single device with a small battery or multiple packs on a global air service. You’ll learn how to classify correctly, confirm testing (UN 38.3) and ratings, choose the right mode and packing instruction (PI 965–970), pick compliant packaging, apply the right marks and labels, complete the documentation, and book with an accepting carrier—without missing operator variations or prohibitions.

What follows is a practical UK and international playbook in 15 concise steps: from shipment classification and state‑of‑charge considerations to quantity limits, overpacks, declarations, customs, and special cases like returns, waste and prototypes. Use it to audit your current process or build a new one that stands up to checks at origin, in transit, and at destination. Let’s get you shipment‑ready.

Step 1. Classify your lithium shipment (chemistry, configuration and UN number)

Before you can decide how to ship lithium batteries safely and legally, you must classify the goods. Identify the chemistry—lithium ion (rechargeable) or lithium metal (primary)—then define the configuration: shipped on their own, packed with equipment, or contained in equipment. This determines the correct UN number, which in turn drives packing instructions, labels, documents, quantity limits, and whether certain air services (e.g., passenger aircraft) are permitted under ICAO/IATA and UK CAA rules.

• Confirm unit type: A cell is a single unit; a battery/pack is two or more cells. Power banks are treated as batteries for regulatory purposes.
• Note device status: If installed in equipment, classify under the appropriate “contained in equipment” entry; if separate but in the same box, it’s “packed with equipment.”
• Include button/coin cells: These still fall under lithium metal/ion rules; if installed in equipment they are typically shipped under UN 3091/3481 as applicable.
• Capture identifiers: Record model/part numbers and manufacturer details to tie classification to test evidence in later steps.

Once you have the correct UN number and configuration, you can verify testing, ratings and state of charge, which govern the packing instruction you must apply next.

Step 2. Confirm compliance testing and ratings (UN 38.3, watt-hours/lithium content, state of charge)

Before you decide how to ship lithium batteries, prove they’re safe and eligible for transport. Regulators and carriers expect documented UN testing, correct ratings on the unit, and—if you’re flying—strict control of the state of charge. This evidence underpins the packing instruction you’ll use and whether your carrier can accept the consignment.

• UN 38.3 evidence: Obtain a UN 38.3 test report or signed certification from the manufacturer/supplier and keep it on file; carriers may request it (UPS requires this for approvals).
• Match IDs: Ensure the tested model/part numbers and descriptions exactly match your cells/batteries.
• Watt‑hour rating (Li‑ion): Verify the Wh rating is marked on the battery; if it isn’t visible, contact the manufacturer (required for most Li‑ion manufactured after 2009/2011 per IATA sections referenced by industry guidance).
• Lithium content (Li‑metal): Confirm lithium content per cell/battery against your chosen mode/operator limits; for example, UK postal limits cap at 1 g per cell/2 g per battery.
• State of charge (air): For lithium‑ion shipped by air, ensure SoC does not exceed 30% per IATA/ICAO rules echoed by major carriers.

With compliant testing and ratings confirmed, you can select the transport mode and apply the right rule set with confidence.

Step 3. Choose transport mode and check the rules (IATA/ICAO for air, ADR for road, IMDG for sea, RID for rail, UK CAA guidance)

Your transport mode determines the rulebook you must follow, so decide this before packing. Air shipments follow ICAO Technical Instructions implemented via the IATA DGR; road uses ADR; sea uses the IMDG Code; rail uses RID. In the UK, the CAA expects lithium battery consignments to be packed, marked, labelled and documented exactly to these frameworks.

• Air (ICAO/IATA): The strictest regime. Cells/batteries shipped alone are generally forbidden on passenger aircraft and move under Cargo Aircraft Only with additional controls; UK CAA highlights that transporting them alone in passenger holds is prohibited. Lithium‑ion by air must not exceed 30% state of charge. Expect operator variations, so confirm acceptance before booking.

• Road (ADR): Widely used for UK domestic and GB–EU moves. Provisions are similar but typically less restrictive than air; any shipment compliant for air is acceptable by road (the reverse isn’t guaranteed). Apply ADR marks, labels and documents as required.

• Sea (IMDG): Global standard for ocean freight with classification, packing, marking, labelling and DG declaration requirements aligned to UN numbers. Generally less restrictive than air but still prescriptive—verify stowage/segregation and documentation.

• Rail (RID): Harmonised with ADR for inland rail corridors. Use the same UN classifications and hazard communication adapted to rail operations.

Choose the mode, then apply the matching packing instruction and any operator or state variations before you proceed.

Step 4. Check prohibitions and operator variations (damaged/defective/recalled, postal limits, carrier pre-approvals)

Before you apply packing instructions, confirm you’re actually allowed to move the goods the way you plan. Lithium battery prohibitions and carrier/operator variations can override the general rules and are a common cause of refusals and delays when learning how to ship lithium batteries.

• Damaged/defective/recalled: Lithium batteries identified as defective for safety reasons are forbidden for air transport; this also applies when installed in recalled devices. Major networks additionally refuse damaged/faulty batteries.
• Postal limits (UK): Royal Mail accepts lithium batteries only when installed in or connected to equipment, with a maximum of four cells or two batteries per package, net 5 kg limit, and lithium content not exceeding 1 g per cell/2 g per battery. Damaged/recalled are prohibited.
• Passenger aircraft bans: Cells/batteries shipped alone are not permitted in passenger aircraft holds; expect Cargo Aircraft Only for many standalone shipments.
• Operator variations: Airlines and integrators publish extra restrictions—check acceptance for your route/service.
• Carrier pre‑approvals: UPS requires pre‑approval for lithium metal batteries shipped alone (UN3090) by air and evidence such as UN 38.3 test reports and packaging details.

If any prohibition applies, consider an alternative mode (road/sea) or consult your carrier/DGSA before proceeding.

Step 5. Apply the correct packing instruction and section (PI 965–970; UN3480/UN3481/UN3090/UN3091)

With classification and mode chosen, select the IATA/ICAO Packing Instruction (PI) that matches your UN number and configuration. Each PI has sections (I/IA/IB/II) that set quantity/size thresholds, documentation, and whether a Shipper’s Declaration is required. Choosing the wrong PI/section is a common reason for carrier refusal when learning how to ship lithium batteries.

• Section II (small consignments): Designed for limited quantities/sizes. Requires the lithium battery mark and a package that can withstand a 1.2 m drop test (noted in industry guidance for PI 966/969 Section II). No Shipper’s Declaration in most cases.
• Section IB/IA/I (larger consignments): For higher quantities/ratings or certain standalone shipments. Shipper’s Declaration is required, and operator variations apply. For air, lithium‑ion SoC must not exceed 30%, and many standalone batteries are Cargo Aircraft Only.
• Mixed equipment scenarios: If a package combines “contained in” and “packed with” equipment under Section II (e.g., PI 966/967 or PI 969/970), ensure all applicable parts of both PIs are met, keep total lithium battery weight within the stated limit (e.g., 5 kg in guidance for combined Section II packages), and include the required “in compliance with Section II of PI…” wording on transport documents.

If you land in IB/IA/I or batteries‑alone PIs (PI 965/968), expect tighter operator controls and, in some networks, pre‑approvals. Lock the PI/section now—your packaging, marks/labels and paperwork will flow directly from it.

Step 6. Select compliant packaging and inner protection (strong outer, cushioning, drop-test capability, overpacks)

Your packaging does the safety heavy lifting. Regulators and carriers expect strong, rigid outers with effective inner protection that prevents movement and damage. If batteries are installed in equipment, the device may provide equivalent protection; if not, you must use robust inner packaging and cushioning. For many small consignments under Section II, the completed package must withstand a 1.2 m drop test.

• Strong outer packaging: Use rigid, good‑quality outers (e.g., double‑walled fibreboard cartons or rigid cases); seal securely with heavy‑duty tape.
• Inner protection and cushioning: Use non‑conductive inner packs and ample cushioning (foam, bubble wrap, cardboard dividers) so items cannot move or contact each other.
• Section II drop test: PI 966/969 Section II packages must be capable of a 1.2 m drop without damage that compromises containment.
• Equivalent device protection: If batteries are contained in equipment, ensure the device affords protection comparable to a strong outer.
• Overpacks: When consolidating compliant packages, use an overpack marked “OVERPACK” and repeat lithium marks/labels on the overpack unless all inner marks/labels remain fully visible.

Well‑built packaging reduces refusal risk and is a visible sign you know how to ship lithium batteries compliantly.

Step 7. Prevent short circuits and accidental activation (terminal protection, isolation, devices powered off)

Short circuits and accidental activation are among the top reasons lithium battery shipments are refused or become unsafe. Whether shipping in the UK or internationally, isolate live terminals, prevent movement, and ensure devices cannot power on during transit. Carriers and IATA guidance expect visible measures: terminals protected, items separated by non‑conductive materials, and equipment powered off and secured.

• Cover terminals: Use non‑conductive caps or tape; never leave bare terminals exposed.
• Individually pack cells/batteries: Place each in inner packaging (e.g., plastic bags) and use cardboard/foam dividers to stop contact.
• Keep metal away: Prevent tools or loose metal from contacting batteries.
• Immobilise contents: Cushion to eliminate movement and vibration that could chafe insulation.
• Power devices off: Fully shut down and tape over switches; pack to prevent accidental activation.
• Secure “packed with equipment” sets: Fix batteries so they cannot shift or touch the device or other batteries.

Step 8. Respect quantity, weight and power limits per package and consignment

The limits you apply depend on chemistry, configuration, mode and your chosen PI/section. They govern how many cells/batteries you may place in one package, the net battery weight allowed, and power thresholds that trigger stricter sections, documentation or carrier refusal. Treat overpacks as logistics convenience only—they never increase per‑package limits when learning how to ship lithium batteries.

• Installed in equipment (UK post): Max four cells or two batteries per package; net 5 kg cells/batteries; lithium content ≤1 g per cell/2 g per battery; damaged/recalled not permitted.
• Section II combined packages: Where “contained in” and “packed with” are combined under Section II, keep total lithium battery weight in any package ≤5 kg and meet both PIs’ parts.
• Overpacks: Quantity/weight limits apply to each inner package; overpacks don’t raise limits. Mark “OVERPACK” if inner marks aren’t visible.
• Standalone air shipments: Expect tighter PI tables and Cargo Aircraft Only limits; follow the PI net quantity per package rules exactly.
• Operator caps: Some services cap to <100 Wh per battery and as few as two per box/four per shipment—check before booking.
• State of charge (air): Lithium‑ion by air must not exceed 30% SoC; treat this as a power limit alongside Wh/lithium content thresholds.

Record counts, net battery weight and ratings on your pack sheet, then verify against the selected PI section and carrier acceptance policy.

Step 9. Mark and label correctly (lithium battery mark with UN number, Class 9, Cargo Aircraft Only, overpack)

Marks and labels tell screeners, handlers and pilots exactly what they’re dealing with. Once you’ve applied the right packing instruction, add only the marks/labels required for that PI/section and mode. Wrong or missing hazard communication is one of the most common reasons lithium battery shipments are held, so be precise when learning how to ship lithium batteries.

• Lithium battery mark (most Section II): Display the lithium battery mark with the correct UN number(s) and a contact telephone number. Minimum size 120 × 110 mm; may be reduced to 105 × 74 mm if the package is too small. You may list multiple UNs on one mark when applicable.
• Exceptions (no lithium mark): Not required for packages that contain only button/coin cells installed in equipment, or for consignments of two packages or fewer where each package contains no more than four cells or two batteries installed in equipment.
• Class 9 label (fully regulated): For IB/IA/I and other fully regulated shipments, apply the Class 9 hazard label in addition to any lithium mark required by your PI/section.
• Cargo Aircraft Only (air): When your PI/section/operator requires it (e.g., many batteries‑alone air shipments), apply the orange “Cargo Aircraft Only” label.
• Overpacks: If you consolidate packages, mark “OVERPACK” and repeat the lithium mark and any hazard labels on the overpack unless all inner marks/labels are clearly visible.

Confirm placement, durability and contrast of all marks/labels; they must be clearly visible and not obscured by tape, straps or documents.

Step 10. Complete the required documentation for your mode (Shipper’s Declaration, AWB entries, IMDG/ADR docs, UN 38.3 test summary)

Documentation proves compliance. Match it to your mode and chosen packing instruction, keep terminology exact, and only add statements the rules require. Have your UN 38.3 evidence ready on file—carriers may request it, even when it isn’t a mandatory transport document.

• Air (IATA/ICAO): Shipper’s Declaration required for fully regulated consignments (e.g., Sections IB/IA/I, many PI 965/968 batteries‑alone). No separate SoC letter—your signed Declaration certifies SoC ≤30% for lithium‑ion. On the AWB, reference dangerous goods and, where applicable, add required statements such as lithium ion batteries, in compliance with Section II of PI966 (or the lithium‑metal equivalent) when Section II combinations demand wording on documentation.

• Road (ADR) and Rail (RID): Prepare the ADR/RID transport document showing UN number, proper shipping name, Class 9, number and type of packages, and net quantity/weight, plus shipper and consignee details.

• Sea (IMDG): Issue a Multimodal Dangerous Goods Form (DGD) with the same core entries (UN, PSN, Class 9, package count/type, net quantities) and sign the shipper’s certification.

• UN 38.3 evidence: Maintain a test report or signed certification matching your exact cell/battery model. IATA does not require an MSDS or the UN 38.3 test data as part of the transport documents, but operators (e.g., for pre‑approvals) may ask to see it.

Ensure all entries mirror your marks/labels and PI section. Discrepancies are a common reason for refusal.

Step 11. Book with an accepting carrier and service (UK domestic and international), and pre-advise dangerous goods

Carriers differ in what they accept and on which services, so secure acceptance before you tender the freight. Pre-book the shipment as dangerous goods, choose the correct service (e.g., Cargo Aircraft Only where required), and confirm route and destination acceptance. Obtain any operator approvals in advance—UPS requires pre‑approval for lithium metal batteries shipped alone by air (UN3090). For UK domestic moves, verify courier vs postal limits; for international moves, check all States involved accept your chosen PI/section. Request a DG pickup slot so screening teams are ready.

• Pre‑advice to carrier: UN/Proper Shipping Name, PI/section, SoC (Li‑ion), cell/battery counts, net battery weight per package, package/overpack totals
• Hazard communication: Which marks/labels applied (lithium mark, Class 9, CAO)
• Docs ready: Shipper’s Declaration or DGD as applicable; AWB notes; UN 38.3 evidence on file
• Contacts: 24/7 or business‑hours number shown on the lithium battery mark
• Variations: Confirm any operator or lane‑specific restrictions are met

Step 12. Ensure training and shipper responsibilities are in place (IATA/IMDG/ADR competence, records, approvals)

You, as the shipper, are legally responsible for full compliance when deciding how to ship lithium batteries. That means only competent, trained personnel may classify, pack, mark/label, declare and book these consignments, with procedures and records to prove compliance. Expect carriers and authorities to ask for evidence—especially on air shipments and batteries shipped alone.

• Training and competence: Ensure role‑specific training under the applicable code (IATA/ICAO for air, ADR for road, IMDG for sea, RID for rail). IATA requires dangerous goods training for Section IB and above; operators (e.g., UPS) ask you to certify staff are properly trained or adequately instructed.
• Defined roles: Authorise who signs the Shipper’s Declaration, prepares packages, applies marks/labels, and books DG. Don’t let untrained staff “help out.”
• Records to keep: UN 38.3 test reports/certifications, training certificates, SOPs, SoC control method (Li‑ion air), packing checklists, copies of Declarations/AWB or DGD, and evidence your package can meet any required 1.2 m drop capability.
• Approvals and variations: Obtain operator pre‑approvals where required (e.g., UN3090 by air with UPS) and document acceptance of any airline/carrier variations.
• Safety screening: Formalise checks to reject damaged, defective or recalled batteries and to verify passenger vs cargo aircraft restrictions.

Embed these controls before you pack—carriers treat missing competence or records as grounds for refusal.

Step 13. Account for customs and destination country restrictions (data, HS codes, local variations)

Even a perfectly packed lithium shipment will stall if the customs data is vague or the destination has tighter rules. Align your export paperwork with the transport classification, and check “State” (country) and operator variations for origin, transit and destination—particularly for batteries shipped alone, which are widely restricted on passenger aircraft and often limited to Cargo Aircraft Only under ICAO/IATA and CAA guidance.

• Use precise product descriptions: e.g., “Rechargeable lithium‑ion battery contained in equipment” or “Lithium‑metal cells packed with equipment.”
• Declare the correct HS code(s): Classify batteries and any host equipment accurately per your tariff; avoid generic “parts” descriptions.
• Include technical identifiers: Model/part numbers, chemistry (Li‑ion/Li‑metal), and, where helpful, Wh rating or lithium content.
• Add regulatory references where accepted: UN number and proper shipping name in invoice notes support risk assessment.
• Provide full customs basics: Value, currency, Incoterms, country of origin, EORI/VAT (where applicable), and consignee details.
• Check destination restrictions: Some countries/operators won’t accept standalone batteries by air without exemptions; choose CAO, road or sea accordingly.
• Pre‑alert variations: Ensure your broker and carrier confirm any local prohibitions before pickup.

Clear, specific data reduces inspections and helps your shipment pass both safety and customs checks first time.

Step 14. Special scenarios: returns/repairs, waste and prototypes (air limitations, road/sea options, DGSA advice)

These are the shipments most likely to be refused. Air rules are strict: lithium batteries identified as damaged/defective or subject to safety recalls are forbidden for air transport, and many networks won’t accept them at all. Stand‑alone batteries face additional passenger‑aircraft restrictions, and a lack of UN 38.3 evidence often blocks air carriage. When planning how to ship lithium batteries in these scenarios, prioritise safety, choose the right mode, and involve a DGSA early.

• Returns for repair (device faulty, battery OK): Permitted (including by air) if you meet the applicable PI, limits and packing; power off, protect terminals (e.g., PI 966/967 or 969/970).
• Damaged/defective/recalled batteries: Do not ship by air; most carriers prohibit. Use specialist ADR/IMDG solutions and consult your DGSA/carrier.
• Waste/end‑of‑life batteries: Expect air restrictions. Prefer ADR or IMDG with robust, compliant packaging and documented handling procedures.
• Prototypes/samples without UN 38.3: Air acceptance is unlikely. Consider road/sea or seek operator/State exemptions well in advance.
• Standalone returns/spares: Check operator variations; many lanes require Cargo Aircraft Only and, for some carriers, pre‑approval.

When in doubt, switch to road/sea and obtain written carrier acceptance after a DGSA review.

Step 15. Run a pre-shipment compliance checklist (end-to-end verification before handover)

This final sweep prevents refusals at the counter or during screening and proves you know how to ship lithium batteries compliantly. Work through it in order, record the outcome, and sign off before you hand the freight to your carrier.

• Classification confirmed: UN 3480/3481/3090/3091 matched to chemistry and configuration.
• UN 38.3 on file: Test report/certification matches exact model/part numbers.
• Ratings verified: Watt‑hours (Li‑ion) or lithium content (Li‑metal) correct; air SoC ≤30% for Li‑ion.
• Prohibitions checked: No damaged/defective/recalled units; passenger‑aircraft bans observed.
• Mode & PI set: Correct PI 965–970 section applied; operator variations reviewed.
• Packaging compliant: Strong rigid outer; non‑conductive inner packs/cushioning; Section II 1.2 m drop capability where required.
• Short‑circuit/activation controls: Terminals covered; items isolated/immobilised; devices powered off.
• Limits respected: Counts and net battery weight per package within PI; overpack not used to exceed limits.
• Marks/labels applied: Lithium battery mark with UN number(s) and phone; Class 9 where fully regulated; Cargo Aircraft Only if required; OVERPACK marked; size ≥120×110 mm (or 105×74 mm for small packs).
• Docs complete: Shipper’s Declaration/DGD/ADR/RID prepared; AWB entries correct; required Section II wording included; UN 38.3 evidence ready to share.
• Carrier acceptance: Pre‑approvals obtained (e.g., UN3090 by air with UPS); service/route confirmed; DG pickup booked.
• Customs data ready: Precise description, HS code, values, parties; destination restrictions checked.

Sign and date the checklist; file it with your shipment record.

Final checks and next steps

You now have a complete, audit‑ready route for shipping lithium batteries: classify the shipment, confirm UN 38.3 and ratings, pick the right mode and PI, build compliant packaging, prevent shorts and activation, respect limits, apply the correct marks/labels, complete documentation, secure carrier acceptance, and finish with a structured pre‑shipment check. Run Step 15 every time—consistency is your best defence against refusals and delays.

To embed this in your operation, turn the steps into routines your team can execute under pressure. Tighten your controls around models, SoC, and carrier variations, and keep evidence on file so acceptance teams can say “yes” quickly. If you handle returns, waste, or prototypes, plan alternate modes early.

• Standardise SOPs and a one‑page checklist for each PI you use.
• Audit all SKUs for matched UN 38.3 evidence and visible Wh/content markings.
• Define SoC control for air and record it.
• Lock in carrier/operator approvals on sensitive flows (e.g., batteries alone).
• Train and authorise the people who pack and sign.

Need expert backup or accredited training? Speak to the specialists at Logicom Hub to upskill your team (IATA/IMDG/ADR, Lithium by mode, DGSA) and stress‑test your process before your next booking.