Safety Standards of Packaging for Lithium-Ion batteries
The Importance of Safety in Lithium-Ion Battery Transport
Materials:
Packaging must be made of durable, non-conductive materials to prevent short circuits.
Clip-Lok SimPak offers returnable steel and wooden packaging for lithium batteries.
Structural Integrity:
Packaging must be designed to withstand mechanical stresses like vibration, impact, and stacking pressure during transit.
Containment of Hazards:
Proper insulation and compartmentalization to separate batteries and avoid contact or movement.
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The UN 38.3 certification, outlined in the UN Manual of Tests and Criteria, Sixth Revised Edition, Sub-Section 38.3, establishes safety and testing requirements for lithium metal and lithium-ion batteries (UN Nos. 3090, 3091, 3480, and 3481) before transportation. The regulation ensures batteries meet stringent safety standards by undergoing specific tests (T.1 to T.8) based on battery type, size, and configuration.
- Testing Requirements: Batteries must pass tests for altitude simulation, thermal, vibration, shock, external short circuit, impact, overcharge, and forced discharge.
- Classification and Variants: Different standards apply to primary (non-rechargeable) and secondary (rechargeable) batteries, with additional criteria for large and small batteries.
- Changes and Retesting: Significant changes in composition, energy capacity, protective devices, or design require retesting.
- Definitions: Terms such as nominal energy, short circuit, venting, leakage, and cycle are standardized to ensure consistency in testing and compliance.
Compliance with UN 38.3 is mandatory for the safe transport of lithium batteries, reducing risks of overheating, fire, or explosion during shipment.
- Group I – Great danger
- Group II – Medium danger
- Group III – Minor danger
Required for most air shipments.
Must pass strength and durability tests (shock, load, pressure changes).
Certified packages bear UN markings indicating compliance.
Packaging must match the hazard classification and physical properties of the material.
General and specific packaging regulations are outlined in Hazardous Materials Regulations (HMR) Part 173 and Part 178.
However, special provisions (Column 7/9 in regulations) may impose additional restrictions.
Identify Proper Shipping Name (PSN) and UN ID from HMR or ICAO TI.
Follow packaging instructions from the Hazardous Materials Table (HMT).
Verify UN markings and compliance with Packing Group requirements.
Ensure packaging closure follows manufacturer’s instructions to maintain integrity. Certified packaging is crucial for regulatory compliance and safe transport of hazardous materials.
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The ICAO Manual on the Regulation of International Air Transport provides comprehensive guidance on the economic regulation of international air transport. It serves as a key reference for ICAO Contracting States, airlines, regulatory authorities, and industry stakeholders, offering a structured approach to managing air transport policies and regulations.
The International Civil Aviation Organization (ICAO) and the International Air Transport Association (IATA)establish strict regulations for the safe packaging and transportation of lithium batteries by air. These rules help prevent fire hazards, short circuits, and potential accidents during aerial transit.
Key Packaging Requirements For Transporting Lithium-Ion Batteries By Air
Lithium-ion (Li-ion) batteries – Rechargeable (used in laptops, phon es, power tools).
Lithium-metal batteries – Non-rechargeable (used in watches, medical devices).
Packing Instructions for Lithium-Ion Batteries
- Batteries must pass UN 38.3 tests, ensuring they withstand shocks, pressure changes, and extreme temperatures.
- Packing Groups: Batteries are assigned a Packing Group II or III, depending on their hazard level.
- Strong, rigid outer packaging (e.g., fiberboard, metal, or plastic containers).
- Non-conductive separators to prevent short circuits.
- Protection against movement inside the package.
- Lithium-ion batteries shipped separately (UN 3480) must have a maximum charge of 30% SoC.
- Class 9 Hazard Label for dangerous goods.
- Handling Labels: “Cargo Aircraft Only” for certain shipments.
- UN Number & Proper Shipping Name (e.g., UN 3480 – Lithium-ion batteries).
- Passenger aircraft have strict limits on lithium battery shipments.
- Cargo aircraft restrictions vary based on watt-hour (Wh) rating and lithium content.
- Damaged or defective batteries are generally prohibited from air transport.
- Excepted quantities may be exempt from full DG regulations if within specific limits.
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ADR Certification
ADR (Agreement concerning the International Carriage of Dangerous Goods by Road) sets strict regulations for the safe transportation of lithium-ion batteries by road in Europe. These rules align with UN Model Regulations and cover classification, packaging, labeling, and documentation.
ADR certification ensures that lithium-ion batteries are packaged, labeled, and transported safely on European roads. Companies must comply with UN 38.3 testing, use ADR-compliant packaging, and follow strict labeling/documentation requirements to prevent hazards during transit.
SP 188 Exemption – Small lithium batteries below 100 Wh (or 2g lithium metal) may be exempt from full ADR regulations if properly packed.
SP 376 – Covers handling of damaged or defective batteries, requiring special approvals.
Key ADR Requirements for Lithium-Ion Battery Packaging
Classification and UN Numbers of Lithium Batteries
- UN-Certified Packaging – Must meet UN 38.3 testing and comply with ADR Packing Instructions (P903, P908, or P909).
- Durability – Packaging must be rigid, impact-resistant, and leakproof.
- Protection Against Short Circuits – Batteries must be packed with non-conductive materials to prevent accidental discharge.
- Weight Limits – Different weight restrictions apply based on watt-hour (Wh) rating and battery type.
- UN 3480 – Lithium-ion batteries (shipped alone)
- UN 3481 – Lithium-ion batteries contained in or packed with equipment
- Class 9 Dangerous Goods Label
- UN Number (e.g., UN 3480)
- Handling Labels for cargo-only shipments
- Special Markings for lithium batteries (if required under ADR Special Provision 188)
- Dangerous Goods Declaration (DGD)
- Shipper’s Declaration for Lithium Batteries
- Transport Emergency Card (TREM Card) for drivers
The International Maritime Dangerous Goods (IMDG) Code is a globally recognized regulatory framework for the safe transportation of dangerous goods by sea. It serves as an extension of the SOLAS (Safety of Life at Sea) Convention, ensuring that hazardous materials are packaged, handled, and transported in compliance with strict international safety standards. Thus, IMDG Code covers lithium batteries transportation by the sea.
The Legal Framework: SOLAS & MARPOL Conventions
The IMDG Code is legally mandated under Chapter VII of the SOLAS Convention, making compliance essential for maritime safety. Additionally, it aligns with the MARPOL Convention Annex III, which regulates the prevention of pollution from hazardous substances carried by sea in packaged form. Together, these regulations enhance environmental protection and minimize the risks of maritime transport accidents.
IMDG Code Certification is essential for shipping companies, logistics providers, and manufacturers involved in the transportation of hazardous goods. By adhering to the IMDG Code, businesses play a vital role in preventing maritime accidents, thereby ensuring the safety of the crew and reducing the risk of environmental harm. Compliance with the Code not only helps avoid legal penalties and potential shipment delays but also ensures that shipping practices are environmentally responsible. Ultimately, obtaining IMDG Code Certification is a key step in maintaining operational safety, legal conformity, and eco-friendly transport practices.
Key Requirements of IMDG Code Certification
IMDG Code Certification ensures that organizations meet the following compliance requirements:
- Use of UN-certified packaging for dangerous goods.
- Proper marking and labeling to indicate hazards (e.g., Class 9 Dangerous Goods Label for lithium-ion batteries).
- Special provisions for segregation of incompatible substances.
- Detailed instructions on container traffic, stacking, and securing to prevent accidents.
- Specific guidelines for handling flammable, toxic, and corrosive substances.
- Strict segregation rules to avoid dangerous chemical reactions.
- Training requirements for personnel involved in handling and transport.
- Security provisions to prevent the unauthorized movement of dangerous goods.
- Mandatory compliance with incident and fire precaution protocols.
- The IMDG Code is updated every two years to keep up with industry developments and UN recommendations.
- Amendments are overseen by the International Maritime Organization (IMO) and the Maritime Safety Committee.
- Training guidelines
- Security provisions (excluding 1.4.1.1, which is mandatory)
- Segregation flow charts and incident handling protocols
- Certain documentation formats and appendix references
Why Choose Clip-Lok SimPak
- Expertise in lithium battery transportation and compliance with lithium battery shipping regulations.
- Proven track record in providing damaged lithium battery packaging for hazardous goods.
- Global presence with solutions trusted across five continents.
Li-Ion Batt Custom Packaging
The Importance and Expansion of Lithium Batteries
Packaging Solutions for Lithium Batteries
Clip-Lok SimPak specialises in high-quality, returnable packaging solutions for lithium batteries. Designed for safety and efficiency, the packaging meets strict international transport regulations, ensuring protection against impact, short circuits, and thermal runaway.