Shipping Lithium-Ion Batteries: UN3480 & UN3481 Regulations
Thursday, September 25, 2025
General
Key takeaways
UN3480 and UN3481 cover different scenarios: batteries shipped alone versus batteries shipped with or contained in equipment.
Safe packaging, proper labeling, and complete documentation reduce risks and delays.
Watt-hour (Wh) limits and “Cargo Aircraft Only” restrictions are critical for air transport.
Common mistakes include mislabeling, missing documentation, and lack of staff training.
Mercury helps companies stay compliant and safe so they can focus on their core business.
Understanding Regulations for Shipping Lithium-Ion Batteries
Lithium-ion batteries power everything from smartphones and laptops to medical devices and industrial equipment. Their high energy density makes them efficient, but also introduces significant risks: overheating, fire, and even explosion. These hazards have led global regulators to set strict rules, primarily under UN3480 and UN3481 classifications.
UN3480 covers lithium-ion batteries shipped on their own.
UN3481 applies to batteries packed with equipment or contained in equipment.
For shippers, the challenge lies in understanding the differences and applying the correct set of rules for packaging, documentation, and labeling. Failure to comply can mean shipment delays, costly fines, and in severe cases, serious safety incidents.
The Importance of Lithium-Ion Batteries
Lithium-ion technology is essential across industries: consumer electronics, healthcare, aviation, and research. Their popularity stems from their rechargeability, durability, and compact size.
But popularity comes with strict oversight. Regulations exist to protect workers handling these shipments, carriers transporting them, and communities along the route. Compliance ensures safety and prevents costly interruptions. For high-stakes industries like healthcare and life sciences, smooth logistics can mean uninterrupted access to critical diagnostic and treatment tools.
UN3480: Regulations for Lithium-Ion Batteries
When shipping lithium-ion batteries without equipment, stricter requirements apply because the risks are higher.
Packaging Guidelines
Batteries must be packed to prevent short circuits, often with non-conductive dividers or caps.
State of charge (SoC) should not exceed 30%, unless a specific exemption is granted.
Outer packaging must withstand shocks, vibration, and pressure changes.
Corrosive or flammable materials should never be packaged in the same container.
By limiting SoC and avoiding incompatible goods like oxidizers, companies reduce the chance of incidents. These requirements protect shipments in transit and lower liability.
Documentation Requirements
Include a Shipper’s Declaration for Dangerous Goods (DGD).
State on the waybill: “Dangerous Goods as per attached Shipper’s Declaration.”
For air shipments, add the “Cargo Aircraft Only” statement to show passenger planes cannot carry the cargo.
Accurate documentation prevents customs delays and avoids fines. Missing or incomplete paperwork is one of the most common causes of shipment disruptions.
Labeling and Marking
Display Class 9 hazard labels on every package.
Add the “Cargo Aircraft Only” label where required.
Ensure all markings, including UN numbers, are clear and durable.
Correct labeling alerts handlers to the risks and ensures carriers apply proper safety protocols.
UN3481: Regulations for Lithium-Ion Batteries Packed with Equipment
UN3481 applies when lithium-ion batteries are inside equipment (like a laptop) or packed with equipment (like spare batteries shipped in the same box).
Packaging Specifications
Place batteries in inner packaging that fully encloses them.
Secure inner packaging within strong outer containers.
Prevent movement and impacts that could trigger short circuits.
Companies may only ship the number of batteries needed to power the equipment, plus two spares. If cells are ≤20 Wh and batteries ≤100 Wh, a DGD is not required. This reduces paperwork for small shipments while maintaining safety
Documentation Considerations
Exceeding the Wh thresholds requires a Shipper’s Declaration.
When batteries are within limits, shipments may move without the DGD, simplifying logistics.
Still, invoices and airwaybills must reflect the shipment accurately
Accurate documentation remains essential to avoid complications during transportation. Companies need to ensure that all paperwork is complete and reflects the specifics of the shipment.
Labeling and Marking Requirements
Apply Class 9 hazard labels where relevant.
Mark packages with UN3481 to clarify classification.
Use the Lithium Battery Handling Label for certain air shipments
These labels make it clear to handlers whether batteries are standalone or associated with equipment.
Risks Associated with Lithium-Ion Batteries
Even when compliant, lithium-ion shipments carry risks:
Counterfeit or old batteries may lack protections and ignite under stress.
Thermal runaway can occur if a cell overheats and triggers a chain reaction.
Air transport fires are difficult to extinguish once started.
The consequences range from delayed deliveries to catastrophic incidents. That is why regulations are non-negotiable.
Compliance Challenges in Shipping Lithium-Ion Batteries
Keeping up with rules is not easy. IATA and IMDG codes are updated yearly, and national regulators add their own layers.
Key challenges include:
Frequent changes in packaging and documentation standards.
Inadequate employee training in dangerous goods handling.
Risk of misclassification—a common error that creates major delays.
For companies in healthcare and life sciences, even small mistakes can delay critical shipments like diagnostic kits or clinical trial supplies.
Best Practices for Lithium-Ion Battery Shipments
To meet regulatory requirements and reduce risk, shippers should:
Train employees in dangerous goods handling.
Always use UN-approved packaging.
Track Wh ratings to determine documentation needs.
Choose carriers experienced in hazardous materials.
Prepare emergency response procedures, including spill kits and fire suppression.
These practices protect staff, customers, and supply chains from avoidable incidents.
How Mercury Can Help Your Business
Shipping lithium-ion batteries is complex, but Mercury simplifies the process.
Expert Guidance: Our specialists stay updated on global rules and provide step-by-step compliance support.
Tailored Solutions: We design shipping strategies for both UN3480 and UN3481 shipments.
Documentation Management: Mercury prepares DGDs and customs declarations, minimizing errors.
Real-Time Tracking: Advanced systems monitor shipments and send alerts for fast responses.
Safety Commitment: From packaging advice to emergency planning, Mercury ensures shipments are secure.
By managing compliance and risk, Mercury lets companies focus on their core mission—innovation, research, and patient care.
Conclusion
Shipping lithium-ion batteries requires particular attention to safety regulations. Understanding the differences between UN3480 and UN3481 is crucial for compliance and risk management. By adhering to these regulations, organizations can operate efficiently and avoid the consequences of non-compliance.
Companies need reliable logistics partners to navigate these complexities. Mercury's expertise in shipping lithium-ion batteries enables clients to focus on their core business activities while ensuring safe transportation. Adopting best practices for shipping lithium batteries can help organizations succeed in the challenging world of logistics.
Contact us today to secure your lithium-ion battery shipments and keep your operations moving safely and compliantly.
