Lithium batteries are classified as dangerous goods (Class 9) under international transport regulations. Their classification, packaging, and acceptance rules are defined by the UN Model Regulations, implemented through IATA Dangerous Goods Regulations (DGR) and IMDG Code.

According to the International Air Transport Association:

“Lithium batteries are dangerous goods and are subject to strict transport requirements depending on their configuration and Watt-hour rating.”

Source: International Air Transport Association (IATA)
Lithium Battery Guidance: https://www.iata.org/en/programs/cargo/dgr/lithium-batteries/

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1. What is UN3480?

UN3480 refers to:

Lithium Ion Batteries shipped by themselves (not contained in equipment)

This classification is defined under the UN Recommendations on the Transport of Dangerous Goods.

Source: United Nations
UN Model Regulations: https://unece.org/transport/dangerous-goods/un-model-regulations

Typical examples:

• Loose lithium-ion battery packs
• Power banks (standalone units)
• Battery modules not installed in devices

Regulatory classification:

• UN Number: UN3480
• Hazard Class: Class 9 (Miscellaneous Dangerous Goods)

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2. What is UN3481?

UN3481 refers to:

Lithium Ion Batteries contained in equipment OR packed with equipment

This classification is defined under the same UN Dangerous Goods framework and implemented through IATA Packing Instructions.

Two subcategories:

• Batteries contained in equipment
• Batteries packed with equipment

Source: International Civil Aviation Organization (ICAO)
Technical framework: https://www.icao.int/safety/DangerousGoods/Pages/default.aspx

Examples:

• Laptops with built-in batteries
• Mobile phones
• Drones
• Tools shipped with spare batteries

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3. IATA Packing Instructions (Critical Section)

According to IATA DGR (Lithium Battery Section):

• PI965 → UN3480 (lithium ion batteries alone)
• PI966 → UN3481 (packed with equipment)
• PI967 → UN3481 (contained in equipment)

Source: International Air Transport Association (IATA)
https://www.iata.org/en/publications/dgr/

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4. UN3480 vs UN3481 – Regulatory Comparison

Feature	UN3480	UN3481
Configuration	Battery alone	Battery with equipment
Risk classification	Higher risk	Lower risk
Air transport control	Strict	More flexible
Packing instruction	PI965	PI966 / PI967

Feature	UN3480	UN3481
Configuration	Battery alone	Battery with equipment
Risk classification	Higher risk	Lower risk
Air transport control	Strict	More flexible
Packing instruction	PI965	PI966 / PI967
Airline acceptance	Limited	Wider acceptance

5. Air Transport Restrictions

According to IATA Dangerous Goods Regulations:

• UN3480 shipments are often restricted to Cargo Aircraft Only
• State of Charge (SoC) limits apply (commonly ≤30%)
• Operator approval is required for most airlines

Source: International Air Transport Association (IATA)
Lithium Battery DGR: https://www.iata.org/en/programs/cargo/dgr/

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6. UN38.3 Testing Requirement

All lithium batteries must pass UN38.3 testing before transport.

This requirement is mandated by the UN Manual of Tests and Criteria.

Source: United Nations Economic Commission for Europe
UN38.3 framework: https://unece.org/transport/dangerous-goods/un-manual-tests-and-criteria

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7. Packaging Requirements (Regulatory Summary)

Both UN3480 and UN3481 require:

• Protection against short circuits
• Strong outer packaging
• Prevention of accidental activation
• Shock and vibration resistance

These requirements are defined in:

• IATA DGR Packing Instructions (PI965–967)
• IMDG Code (for sea freight)

Source: International Maritime Organization
IMDG Code: https://www.imo.org/en/OurWork/Safety/Pages/DangerousGoods.aspx

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8. Key Operational Difference

UN3480 (higher control):

• Requires stricter airline approval
• More frequently rejected if documentation incomplete
• Higher inspection rate

UN3481 (lower control):

• Higher acceptance rate in global air cargo
• More flexible routing options

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The distinction between UN3480 and UN3481 is defined by international regulatory frameworks under:

• UN Dangerous Goods Model Regulations
• IATA Dangerous Goods Regulations (DGR)
• ICAO Technical Instructions

Correct classification directly determines:

• Whether cargo is accepted or rejected
• Applicable packing instruction (PI965–967)
• Airline approval requirements
• Safety compliance level

For international logistics operators, strict adherence to these regulations is essential for safe and compliant lithium battery transport.

Lithium batteries power modern global supply chains—from smartphones and laptops to electric vehicles and industrial equipment. However, despite their widespread use, international transport of lithium batteries is heavily regulated due to safety risks such as fire hazards and thermal runaway.

This guide explains how to ship lithium batteries internationally in compliance with global standards, including IATA Dangerous Goods Regulations, as well as carrier-specific requirements from  UPS Official Website,  DHL Official Website, and  IATA Official Website.

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1. Why Lithium Batteries Are Regulated

Lithium batteries are classified as dangerous goods because they contain high energy density electrolytes that can:

• Overheat under pressure or damage
• Catch fire if short-circuited
• Explode under extreme conditions
• Produce toxic gases when burning

As a result, international transport is governed under strict frameworks such as:

• IATA Dangerous Goods Regulations (DGR)
• UN Recommendations on the Transport of Dangerous Goods
• IMDG Code (for sea freight)
• ICAO Technical Instructions (for air cargo)

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2. Classification of Lithium Batteries

Understanding classification is essential before shipping.

2.1 Lithium-ion Batteries (Rechargeable)

Common in electronics and EV systems.

• UN3480: Lithium-ion batteries shipped alone
• UN3481: Lithium-ion batteries packed with or contained in equipment

2.2 Lithium-metal Batteries (Non-rechargeable)

Used in sensors, medical devices, and backup systems.

• UN3090: Lithium metal batteries shipped alone
• UN3091: Lithium metal batteries contained in equipment

Each classification determines packaging, labeling, and documentation requirements.

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3. Key Regulatory Framework (IATA)

The most important global standard for air transport is the IATA Dangerous Goods Regulations.

IATA Dangerous Goods Regulations Overview

Key packaging instructions:

• PI 965 → UN3480 (lithium-ion batteries only)
• PI 966 → UN3481 (packed with equipment)
• PI 967 → UN3481 (contained in equipment)
• PI 968 → UN3090 (lithium metal batteries only)
• PI 969 → UN3091 (packed with equipment)
• PI 970 → UN3091 (contained in equipment)

IATA also defines:

• State of charge (SoC) limits (e.g., max 30% for cargo aircraft for UN3480)
• Watt-hour limits
• Cell vs battery thresholds
• Packaging performance standards (drop test, crush resistance)

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4. Shipping by Air (Most Restrictive Mode)

Air transport has the strictest rules due to safety risks.

4.1 General Requirements

• Strong outer packaging (UN-certified if required)
• Individual protection against short circuit
• Non-conductive inner packaging
• Battery terminals insulated
• Shock-resistant packaging design

4.2 Documentation

• Shipper’s Declaration for Dangerous Goods (if applicable)
• Air Waybill (AWB)
• MSDS / SDS (Material Safety Data Sheet)
• UN number and proper shipping name

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5. Shipping by Sea (Less Restrictive but Still Regulated)

Sea freight follows IMDG Code rules.

Key advantages:

• Higher quantity allowances
• Less restrictive SoC limits
• Lower cost for bulk shipments

However:

• Requires Class 9 hazardous labeling
• Must follow segregation rules in containers
• Fire suppression considerations onboard vessels

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6. Carrier-Specific Requirements

6.1 UPS Requirements

UPS
UPS Lithium Battery Shipping Guidelines

UPS requires:

• Compliance with IATA or ADR regulations
• Proper UN labeling (Class 9 hazard label)
• Pre-approval for certain battery shipments
• Restrictions on standalone lithium-ion batteries by air
• Specific packaging instructions depending on watt-hour rating

UPS also prohibits or restricts damaged or recalled batteries.

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6.2 DHL Requirements

DHL
DHL Dangerous Goods Guidelines

DHL Express follows strict acceptance rules:

• Lithium-ion batteries must comply with Section II or Section IA/IB of IATA DGR
• Mandatory safety documentation for air transport
• Packaging must pass UN performance standards
• Restrictions vary by country destination
• Battery testing summary may be required for large shipments

DHL is particularly strict on e-commerce lithium battery shipments.

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7. Packaging Requirements (Critical Section)

Proper packaging is the most important compliance factor.

7.1 Individual Cell Protection

Each battery must be:

• Fully insulated
• Separated from conductive materials
• Wrapped in non-conductive material

7.2 Outer Packaging Standards

Must meet:

• Drop test resistance
• Stack load strength
• Vibration resistance
• Compression resistance

7.3 Hazard Prevention Measures

• No loose batteries inside boxes
• No movement during transport
• Use of anti-static bags
• Fire-resistant liners (recommended for high-risk shipments)

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8. Labeling Requirements

All lithium battery shipments must include:

• Class 9 Hazard Label
• Lithium Battery Handling Label
• UN Number (UN3480 / UN3481 / UN3090 / UN3091)
• Proper Shipping Name
• Sender and receiver details

For air transport, additional marks may include:

• Cargo Aircraft Only label (if required)
• State of Charge indication (for UN3480 shipments)

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9. Common Mistakes in Lithium Battery Shipping

Many shipments are rejected due to:

• Incorrect UN classification
• Missing labels
• Non-compliant packaging
• Incorrect watt-hour declarations
• Mixing damaged and normal batteries
• Failing to follow carrier acceptance rules

These mistakes often lead to delays, fines, or shipment destruction.

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10. Best Practices for Compliance

To ensure smooth international shipping:

• Always verify UN classification first
• Use certified UN packaging materials
• Follow IATA DGR updates annually
• Work with experienced freight forwarders
• Pre-check destination country regulations
• Maintain complete documentation records

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Shipping lithium batteries internationally requires strict compliance with global safety regulations and carrier-specific rules. Whether using air or sea freight, understanding UN classifications, packaging standards, and documentation requirements is essential to avoid delays and ensure safety.

By aligning with frameworks from  IATA, and logistics providers like  UPS and  DHL, shippers can significantly reduce risk and ensure smooth global transportation.

Lithium-ion batteries are widely used in electric vehicles, energy storage systems, consumer electronics, medical devices, drones, and industrial equipment. When these batteries are shipped separately — not installed in equipment — they are classified as UN3480 Lithium Ion Batteries, one of the most strictly regulated dangerous goods categories in international transportation.

At  BatteryShipping.com, we specialize in compliant international battery logistics and dangerous goods transportation. This guide explains the key UN3480 shipping requirements based on current regulations from  IATA,  UPS,  FedEx, and  DHL.

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What Is UN3480?

UN3480 refers to:

Lithium Ion Batteries shipped by themselves (not packed with or contained in equipment).

This classification includes:

• Rechargeable lithium-ion batteries
• Lithium polymer batteries
• Power banks
• EV battery modules
• Energy storage batteries
• Industrial lithium battery packs

UN3480 is classified as:

• Class 9 Dangerous Goods
• Subject to strict air transport restrictions
• Regulated under IATA Dangerous Goods Regulations (DGR)

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Why UN3480 Batteries Are Highly Regulated

Lithium-ion batteries can generate intense heat, catch fire, or explode if:

• Damaged
• Improperly packaged
• Short-circuited
• Overcharged
• Exposed to extreme temperatures

Because thermal runaway incidents on aircraft can be catastrophic, airlines and couriers impose strict transport requirements for UN3480 shipments.  

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UN3480 Packaging Requirements

1. Use Strong Outer Packaging

UN3480 batteries must be packed in:

• Strong rigid outer cartons
• UN-certified packaging for fully regulated shipments
• Packaging capable of passing drop and stacking tests

Most carriers require packaging compliant with:

• IATA Packing Instruction PI965
• UN38.3 tested batteries

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2. Prevent Short Circuits

Battery terminals must be protected by:

• Non-conductive caps
• Individual plastic bags
• Blister trays
• Terminal taping

Batteries must not contact:

• Metal objects
• Other batteries
• Conductive surfaces

Improper terminal protection is one of the most common reasons for shipment rejection.

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3. Internal Protection Against Movement

The batteries inside the carton must be secured using:

• Foam inserts
• Corrugated dividers
• Bubble cushioning
• Molded trays

Movement during transport can damage cells and increase fire risk.

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State of Charge (SoC) Requirement

For air transport, UN3480 lithium-ion batteries must generally be shipped at:

Maximum 30% State of Charge (SoC)

This requirement applies under IATA PI965 Section IA and IB.

Shippers may need special approval for batteries exceeding 30% SoC.

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UN38.3 Test Requirement

All lithium-ion batteries transported internationally must comply with:

UN Manual of Tests and Criteria, Part III, Sub-section 38.3

This includes testing for:

• Altitude simulation
• Thermal testing
• Vibration
• Shock
• External short circuit
• Impact/crush
• Overcharge
• Forced discharge

Without UN38.3 test reports, many carriers will refuse shipment entirely.

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Required Labels and Marks for UN3480

UN3480 shipments normally require:

Mandatory Labels

• Class 9 Lithium Battery Label
• Cargo Aircraft Only (CAO) Label
• UN3480 Marking
• Handling labels where applicable

The labels must be visible, durable, and properly sized according to IATA regulations.

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Required Shipping Documents

Depending on battery type, quantity, and packing instruction, documents may include:

Common Documentation

• Shipper’s Declaration for Dangerous Goods (DGD)
• Air Waybill (AWB)
• MSDS/SDS
• UN38.3 Test Summary
• Packing List
• Commercial Invoice

Fully regulated shipments require trained dangerous goods personnel to prepare documentation.

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IATA PI965 Sections Explained

UN3480 air shipments are usually transported under:

Section	Description	Regulation Level
Section IA	Fully regulated large batteries	Highest
Section IB	Small batteries but still regulated	Medium
Section II	Mostly phased out/restricted for standalone batteries	Limited

Many airlines no longer accept standalone UN3480 Section II shipments because of safety concerns.

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UPS UN3480 Shipping Requirements

UPS Lithium Battery Shipping Information

UPS requires:

• Approved dangerous goods account
• Proper dangerous goods training
• UN-compliant packaging
• Correct labeling and documentation
• Compliance with IATA and ICAO rules

UPS may restrict:

• Damaged batteries
• Recalled batteries
• Prototype batteries
• Large standalone lithium battery shipments

UPS also applies additional operational restrictions depending on destination country and service type.

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FedEx UN3480 Shipping Requirements

FedEx Lithium Battery Shipping Guide

FedEx states that:

• UN3480 batteries are fully regulated dangerous goods
• Many shipments require dangerous goods contracts
• Packages must use rigid outer packaging
• Batteries exceeding 35kg require special arrangements
• Defective or recalled batteries are prohibited

FedEx also follows IATA PI965 requirements and operator variations.

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DHL UN3480 Shipping Requirements

DHL Dangerous Goods Services

DHL Express generally requires:

• Dangerous goods approval
• Pre-approved shipper accounts
• Certified packaging
• IATA-compliant labeling
• DG-trained staff

Some DHL services restrict standalone UN3480 batteries entirely or only allow them under cargo aircraft conditions.

Carrier acceptance often depends on:

• Battery watt-hour rating
• Quantity per package
• Route availability
• Airline restrictions

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Common Reasons UN3480 Shipments Are Rejected

The most frequent problems include:

• Missing UN38.3 reports
• Incorrect labels
• SoC above 30%
• Weak packaging
• Missing dangerous goods declaration
• Improper battery classification
• Mixed dangerous goods incompatibility
• Damaged batteries

Even experienced exporters frequently encounter delays due to documentation or packaging errors.

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Air Freight vs Sea Freight for UN3480

Method	Advantages	Limitations
Air Freight	Faster transit	Strict regulations and higher cost
Sea Freight	Lower cost for large batteries	Longer transit time
Road Freight	Flexible regional transport	ADR compliance required in Europe

Large energy storage batteries and EV battery packs are increasingly transported by sea due to air cargo restrictions.

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Professional UN3480 Shipping Support

International lithium battery shipping is highly technical. Requirements may vary depending on:

• Battery chemistry
• Watt-hour rating
• Net weight
• Packaging configuration
• Destination country
• Airline policy
• Courier operator variations

At  BatteryShipping.com, we help customers manage:

• UN3480 battery shipping
• DG packaging solutions
• Air freight and sea freight
• Dangerous goods documentation
• UN38.3 compliance support
• Global battery logistics

Whether you are shipping small lithium battery packs or large industrial energy storage systems, compliant transportation is critical for safety, customs clearance, and successful delivery.

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References

IATA

• IATA Lithium Battery Guidance Document

FedEx

• FedEx Lithium Battery Shipping
• FedEx Dangerous Goods Lithium Battery Guide

UPS

• UPS Hazardous Materials Guide

DHL

• DHL Dangerous Goods Services