3480 - Lithium Ion Batteries
Flaviano Bada
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The UN 3480 label is used to identify the package as containing a lithium battery that is in compliance with the appropriate regulations and standards, and to indicate that it may still pose a hazard during transportation. The label contains the UN number, the proper shipping name, and the hazard class of the material being shipped.
UN 3480 applies to packages that contain lithium ion or lithium polymer batteries that have been tested and certified as being in compliance with certain standards and regulations, and therefore do not pose as significant a risk during transportation.
Battery labels are a legal requirement to label packages containing lithium batteries with the appropriate UN 3480 label when they are being transported by air, sea, or road, to ensure the safe handling and transportation of the hazardous material.
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Note: Answers to some of the questions I asked may not be necessary. However, when classifying lithium cells or batteries for transportation I have found it better to have too much information than too little.
Please see below for a summary of the regulatory requirements based on the available information. I am providing information solely for transport by ground within the U.S. subject to USDOT/PHMSA regulations for commercial carriers (FedEx, UPS). I am not considering transport by USPS. (I find their regulations confusing and many postal personnel do not know them properly resulting in confused shipping).
These batteries may be transported by air anywhere in the world subject to the regulations of the International Air Transport Association (IATA). I am familiar with the IATA Dangerous Goods Regulations but they are not considered here. Learn more about ICAO & IATA.
A single cell (AA, AAA, C, 18650, etc., usually referred to as a battery by consumers) may be defined as a single encased electrochemical component and a battery (power drill battery, power pack, drone battery, etc.) is two or more cells electrically connected. Rechargeable lithium-ion cells and batteries are manufactured in various shapes, sizes, and chemistries depending on the application. The image below: Variety of Lithium-Ion Cells shows examples of cells that may be packaged according to UN 3480.
Lithium-ion cells and batteries are capable of overheating and undergoing a process called thermal runaway. Thermal runaway can occur without warning as a result of various factors, including if the package is damaged, overheated or improperly packed. Thermal runaway can also occur on its own due to manufacturing defects, without any environmental or mishandling factors. See video: Battery Thermal Runaway
The outcome of thermal runaway varies depending on the specific chemistry of lithium-ion, the size of the cell or battery, state-of-charge (SoC) level, the individual manufacturer design as well as orientation and configuration in the package. The more dangerous hazards can include violent ejection of flames and battery components, emission of flammable gas that can build up and later explode or an explosion of the cell itself. Less hazardous outcomes include an emission and dissipation of flammable vapors without ignition or accumulation of gas or a thermal runaway event that catches fire but self-extinguishes. See videos: Large Format Cell Thermal Runaway and Slow Motion Thermal Runaway. Research on flammable gasses released: Flammable Gases
UN 3480 governs the shipment of rechargeable lithium-ion cells or battery packages. The associated packing instructions are P.I. 965. Within P.I. 965, lithium-ion cells or batteries can be packaged and shipped according to: Section 1A, Section 1B or Section II. (Packing Instruction 965). An example of a package prepared for transportation with proper labeling and packaging is shown here: Image of a UN 3480 Box Ready for Transport
UN 3480 can encompass a variety of different types and configurations of lithium-ion cells and batteries, making it difficult to assess the hazard associated with the package simply by looking at the label alone. For example, a shipment of cells or batteries posing a significant thermal runaway hazard may use the same packaging and labeling as a shipment containing comparatively safe and benign lithium-ion cells and batteries. It is important to keep this in mind when creating a safety management plan for the transportation of lithium-ion cells and batteries.
Since 2016, when the International Civil Aviation Organization (ICAO) implemented drastically more restrictive global regulations on shipping lithium batteries by air, shippers have adapted and done their best to comply. Meanwhile, regulatory agencies continue to update regulation in an effort to keep lithium battery transport by air as safe as possible.
The most recent change took effect January 1, 2022, with the removal of Section II provisions from IATA Packing Instructions PI 965 and PI 968 in the 63rd Ed. of the DGR. This revision means that all packages containing any number of standalone lithium-ion or lithium-metal batteries will be Fully Regulated shipments under Section IB of the packing instructions. See below for more details.
Since lithium metal batteries (UN3090) were already prohibited, the new regulation meant no standalone lithium batteries, in any quantity or packaging, could be shipped as cargo on passenger aircraft. There is still no compliant way to do so without a special permit or other approval from a competent authority.
The March 2019 PHMSA IFR harmonized United States lithium-ion battery transport regulations with those of the ICAO, along with extra requirements for ground shipments to ensure no lithium-ion batteries were loaded on aircraft contrary to the regulations. For more detail and current updates on these and other regulations, you can bookmark our Lithium Battery Resources page.
Note: These restrictions apply only to standalone lithium-ion batteries and commercial aircraft. You can still compliantly ship lithium batteries, including lithium-ion batteries, by air. See below.
Section II of Packing Instructions PI 965 and PI 968 was created to let shippers ship packages containing one or two small batteries by air with fewer restrictions, and by people without extensive Dangerous Goods training.
While these restrictions may feel complex and burdensome, you can find quick guidelines for compliantly shipping any type of lithium batteries (by any mode) using our Lithium Battery Advisor software.
Plus, all lithium batteries may still be compliantly transported on cargo-only aircraft, subject to regulations. However, you should be aware that airlines may have variations in place that restrict lithium battery transport, even on cargo aircraft.
Meanwhile, at the direction of the ICAO, the SAE International G-27 Lithium Battery Packaging Performance Committee continues its efforts to define a standard that may allow shippers to once again transport standalone lithium batteries as cargo on passenger aircraft in the future. That standard, however, is still likely at least a year away.
Lithium will not burn. The solid oxygen in the matrix will not burn. Any lithium cell overcharged or over discharged can heat up enough to cause the O2 to change back into a gas which can burn if hot enough. This happens when a Lipo cell pillows. What is the danger?
The big problem is not the cell as much as the BMS. The safest pack is one that uses an Active BMS and not the cheaper Passive type like Telsa cars tried. Thus a stored device like a laptop can be more dangerous than an actual bulk cell in shipping. The only safe storage is cool, dry with an oxygen suppressant extinguisher. Example: we use a safe starch foam type in our electric airplane that instantly stops flames and smoke without removing O2 from the pilot. It cleans up with water if ever needed.
I disagree with your characterization that 30% SoC (state of charge) level is synonymous with 30% of full voltage. That would indeed kill the battery. An empty battery is considered at 0% state of charge and will be at about 3.0 V. From there you can easily go to a 30% SoC, which will be roughly at 3.2 V per cell.
Hi All documentation including from IATA i have looked at is telling me i can only send 2 lithium ion batteries in a package.Batteries are under 100 watt hours and at 30% state of charge is this correct.
The same rules apply regardless of how large the battery is. If the > 1KWh lithium ion battery is installed in the equipment it would be UN3481, and if the battery is > 35 kg then air transport would not be possible without Competent Authority Approval(s).
Hi I would like to either send or carry as baggage on the plane to Colombia from Mass. a ebike 36 volts by 10.4 AH in a foldable aluminum frame with a total weight bat included 40 lbs. The battery is totally contained in the frame. What say you kind sir?
I have 2 packages containing 132 laptops with lithium ion batteries contained in them, all batteries are under 100 Wh and all laptops are securely packed. Do I need to register shipment as DGR and also what regulations would I need to comply with to ship by air and by sea?
Yes, this would be DG. The shipper would comply with the IATA Dangerous Goods Regulations (IATA DGR) for air and the IMDG Code for Ocean. See our training course here: -battery-shipping-online-hazmat-training/shipping-fully-regulated-and-excepted-lithium-shplb?returnurl=%2fshop%2ftraining%2flithium-battery-shipping-online-hazmat-training%2f
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