Pack Ship Batteries

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HOW TO SAFELY PACKAND SHIP BATTERIESPUBLISH DATE: MAY 22, 2012


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2012 United Parcel Service of America, Inc. UPS, the UPS brandmark and the color brown are registered trademarks of United Parcel Service of America, Inc. All rights reserved. 5/12

HOW TO SAFELY PACK

AND SHIP BATTERIES

PUBLISH DATE: MAY 22, 20

Although they are very common today in portable electron-ics, tools and other applications, batteries can be a sourceof dangerous heat, sparks or re if they are improperlypackaged for shipping. For this reason, UPS customers mustfollow applicable safety regulations and appropriate precau-tions when preparing batteries for transportation. Batteryshipments may be subject to both U.S. and internationalsafety regulations, and because of the potential dangersassociated with violations of those regulations, people whodo not follow the regulations when packing their shipmentscould be subject to nes or other penalties.

UPS has assembled these guidelines to help you safely packand ship many kinds of batteries. In some cases, such aswith alkaline or certain nonspillable lead-acid batteries,your responsibilities may be limited to simple steps suchas: selecting strong outer packaging; carefully protectingbattery terminals to prevent sparking or short circuit; andcarefully preparing the interior package components to keeptools or other metal objects away from batteries.

Other types of batteries, including lithium ion and lithmetal types, also may be fully regulated as hazardous m(also known as dangerous goods) for transportation, sin addition to those basic safety precautions they requuse of specialized packaging, specic hazard labelingspecic documents certifying compliance with the appregulations.

As you review this brochure, please be aware of how shipping practices comply with the guidance given heand understand that some of your batteries may requiyou to review and comply with the U.S. Department oportation (DOT) Hazardous Materials Regulations (Tof the Code of Federal Regulations) and/or the InternaAir Transport Association (IATA) Dangerous Goods Regula(DGR). The IATA DGR is based on and produced in cotion with theInternational Civil Aviation Organization Technical Instructions. Additionally, other international latory requirements apply, such as the International MDangerous Goods (IMDG) Code, and the ADR DangGoods Regulations for European Road Transport.


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PROTECT BATTERIES AND TERMINALS

When shipping almost any battery, you must protect all terminals againstshort circuits that can result in res. Protect terminals by completelycovering them with an insulating, non-conductive material (e.g., usingelectrical tape or enclosing each battery separately in a plastic bag),or packing each battery in fully enclosed inner packaging to ensureexposed terminals are protected.

Package the batteries to keep them from being crushed or damaged,and to keep them from shifting during handling.

Always keep metal objects or other materials that can short circuitbattery terminals away from the batteries (e.g., using a separateinner box for the batteries).

Note: To prevent re, any device with installed batteries must not turnon while in transport. Protect switches that can be accidentally activatedor remove the batteries and protect the terminals. Even very simple deviceslike ashlights or rechargeable drills can generate a dangerous amountof heat if accidentally activated.

TYPES OF BATTERIES

There are a variety of batteries available today and, while in tramany are regulated as hazardous materials (also known as danggoods) that may only be shipped with UPS by shippers with cofor hazardous materials/dangerous goods service.

IDNumber

Proper Shipping Nameand Description

HazardClass

PackinGrou

UN2794 Batteries, Wet, Filled with Acid 8

UN2795 Batteries, Wet, Filled with Alkali 8

UN2800 Batteries, Wet, Non-Spillable 8

UN3028 Batteries, Dry, ContainingPotassium Hydroxide Solid 8 II

UN3090 Lithium Metal Batteries 9

UN3091Lithium Metal Batteries Containedin Equipment or Lithium MetalBatteries Packed with Equipment

9 II

UN3292 Batteries, Containing Sodium 4.3

UN3480 Lithium Ion Batteries 9

UN3481Lithium Ion Batteries Containedin Equipment or Lithium IonBatteries Packed with Equipment

9 II

Some of the battery types shown above may be shipped under rtory exceptions that do not require full compliance with the hazmaterials/dangerous goods regulations. In addition, there are sobattery types (e.g., conventional dry cell or alkaline batteries insumer sizes) that are not regulated at all, provided they are adeqprotected against short circuit.


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Wet Batteries (UN2794 and UN2795) Not accepted in UPS small

package services; permitted in UPS air freight and UPS ground freightThese batteries are commonly used in cars, electric wheelchairs, fork-lifts, some continuous computer power sources and other applications.They contain highly corrosive acid or alkali and can cause res fromshort circuit. All terminals must be protected against short circuit, andthe batteries packaged and tested according to49 CFR 173.159 for U.S.shipments, orIATA Section 5, Packing Instruction 870 (2011 edition).Note that air shipments must include an acid- or alkali-proof liner, orinclude supplementary packaging with sufcient strength and adequateseals to prevent leakage of electrolyte uid in the event of spillage (seeFigs. 1 and 2). Applicable shipping paper/Declarations for DangerousGoods requirements must be met.

Nonspillable Batteries (UN2800)

These batteries may not be subject to the Hazardous Materials Regu-lations if they meet the pressure differential and vibration testing in49 CFR 173.159, as well as being plainly and durably marked eitherNONSPILLABLE or NONSPILLABLE BATTERY on the outer packaging(see Fig. 3). Conformance with49 CFR 173.159a is mandatory and thebatteries must be prepared for transport so as to prevent short circuitand unintentional activation of any devices or equipment in the package.

Shipments of non-spillable acid or alkali batteries performed uIATA Dangerous Goods Regulations must be fully declared andto the requirements ofPacking Instruction 872 (2011 edition).

Non-spillable acid or alkali batteries that comply with certain ad

testing are not subject to any regulations, provided the terminalprotected against short circuit. These additional requirements, wstated in49 CFR 173.159a(d) and inIATA Section 4.4, Special ProvA67, require that the battery contain no free-owing liquid, and electrolyte must not ow from a cracked case at 55C (131F). Theand package should be marked NONSPILLABLE or NONSBATTERY.

Fig. 1Sample Outer Packaging Wet Batteries

Non-ConductiveDivider

Insulating Cap

Terminal Protection

Inner Container

Strong OuterPackage

Fig. 2Sample Packaging Multiple Wet Batteries

Fig. 3Sample PackagingNonspillable Batteries


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Dry Batteries, Containing Potassium Hydroxide Solid (UN3028)

In the U.S., these batteries must be prepared according toSpecialProvision 237 in 49 CFR 172.102, which states that UN3028 materialsmust be prepared and packaged in accordance with the requirementsof173.159(a), (b), and (c). For transportation by aircraft, the provisionsof173.159(b)(2) are applicable. International air shipments of thesetypes of batteries must conform toIATA Packing Instruction 871(2011 edition).

Batteries, Containing Sodium (UN3292)These batteries are not accepted in the UPS package environment.

Lithium Batteries (UN3090, UN3091, UN3480, UN3481) Note: In the U.S., regulations governing the shipment of lithium batteriesare expected to change in early 2011. Readers of this information areurged to monitor the work of the U.S. Department of Transportations Pipeline and Hazardous Materials Safety Administration (PHMSA) forup to date information. Consult the following PHMSA web site for more information:http://hazmat.dot.gov.

About Shipping Lithium Batteries by Air ServiceThere are two kinds of lithium batteries, both of which contain very highlevels of energy, usually in small cases:

Lithium ion (Li-ion) batteries, which are rechargeable. This type ofbattery includes those referred to as lithium polymer (Li-Po) batter-

ies. Sometimes, these are also called secondary lithium batteries. Lithium metal batteries, which are non-rechargeable. These are also

sometimes called primary lithium batteries.

Because lithium batteries are designed to provide high levels of power,the electrical energy in these batteries is signicant, meaning thatsuch batteries can sometimes generate a great amount of heat if shortcircuited. In addition, the chemical contents of these batteries maycatch re if damaged, or improperly designed or assembled. For thesereasons, there are safety regulations controlling the shipment of thesetypes of batteries. Shippers must conform to the applicable sections ofthe U.S. Hazardous Materials Regulations and/or international regula-tions such as theInternational Air Transport Associations DangerousGoods Regulations.

While both of these types of lithium batteries are classied as hazardous materials (also referred to as dangerous goods), there are exceptions forcommon small sizes of these batteries that simplify the rules for ship-ping these items. This document describes the rules for shipping thesesmall lithium batteries.

Lithium Metal Excepted

Cells must not contain more than 1.0 g of lithium metal;

Batteries must not contain more than 2.0 g of lithium metal

Lithium Ion Excepted

In the U.S. rules Cells must not exceed 1.5 g of equivalent lithium conten Batteries must not exceed 8 g of equivalent lithium cont

You may calculate equivalent lithium content by multiplycells ampere-hours by 0.3. Since most small batteries are mawith milliampere-hours, you must rst divide milliampere-hours

by 1,000 before multiplying the result by 0.3. In the international rules Cells must not exceed 20 Watt-hours; Batteries must not exceed 100 Watt-hours.You may calculate Watt-hours by multiplying ampere-hoursvoltage. Since most small batteries are marked with milliam

hours, you must rst divide milliampere-hours by 1,000 befo multiplying the result by the batterys voltage.

Shipments of larger batteries are not given these exceptions andare thus fully regulated, and must be prepared as such. UPS req

a contract for shipment of these regulated hazardous materialsdangerous goods. Restrictions apply to the types of hazardousmaterials/dangerous goods carried, and the service territory avaifor these shipments.

Note: In recent years, there have been occasional recalls of defelithium batteries. Never send recalled lithium batteries by air; dso can be very dangerous and may result in nes or penalties agyou, the sender. In addition, UPS does not transport recycled baby air. UPS air services that have the potential to travel by air inUPS Next Day Air, UPS 2nd Day Air, UPS 3 Day Select, InternationExpress and International Expedited. UPS Ground service betw

Alaska, Hawaii or Puerto Rico and the continental U.S. is unavfor either recalled or recycled batteries, as shipments in these lamust travel by aircraft for at least one ight segment.

Shipping Lithium Batteries Without Electronic EquipmentThe rules for shipping small lithium batteries differ, dependingtype of battery involved and the type of battery you wish to senstrictest rules apply to lithium metal batteries. Regardless of thtype, one of the most important steps in preparing any battery fment is to protect against short circuits.


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Lithium Batteries (UN3090, UN3091, UN3480, UN3481) (cont.)

Short Circuit ProtectionAs they are packed, batteries must be protected against short circuits(see Fig. 4). There are various ways of accomplishing this protection.For example, many batteries are sold in blister packs that provide therequired protection. Other options include placing single batteries intoa plastic bag (without other contents), putting non-conductive tape overbattery terminals, or utilizing a design that recesses terminals enoughthat they cannot come into contact with conductive materials or otherbattery terminals. Never pack metal objects or other conductive itemsinto the same package with batteries if there is an opportunity for thoseobjects or items to come into contact with the batteries terminals. If it

is necessary to send tools or other items with the batteries, separatelycontain properly protected batteries in a small box within a larger pack-age that you use for the other items.

Small Lithium Metal Batteries The chemistry of these batter

poses great re risks when they are short-circuited, or if thesomehow damaged. For this reason, they must never be transpaboard passenger aircraft and must be marked to warn aboucontents. Whether you plan to ship these batteries by air (in UPS system or any ight to, from, within or through the U.or ground (in the U.S.), the package must be marked with eiof the two following statements (in letters at least 6 mm higfor packages of up to 30 kg (66 lb) gross weight or 12 mm hifor heavier packages):

PRIMARY LITHIUM BATTERIESFORBIDDEFOR TRANSPORT ABOARD PASSENGER AIRCR

orLITHIUM METAL BATTERIESFORBIDDEN

FOR TRANSPORT ABOARD PASSENGER AIRCR

Packagings used for battery shipments need to be rugged enokeep the contents from being crushed. For this reason, interrules always require a package that is capable of being drop1.2 meters (approximately 4 feet) without breaking open or dthe batteries. This same requirement applies in the U.S. when contain more than 24 lithium cells or more than 12 lithium bStrictly within the U.S., the gross package weight must not 30 kg (66 lb). Any international shipment must be restricted topackage weight of 2.5 kg (5.5 lb).

It is important to provide the necessary warnings on the outof a package containing lithium batteries. International regurequire that any package of lithium metal batteries display ative label (110 mm x 120 mm); the label may be reduced in sfor smaller packages (74 mm x 105 mm):

Blister Pack

Cushioning

Divider

Fig. 4Sample Packaging Lithium Batteries

Lithium Metal BatteryDO NOT LOAD OR TRANSPORT

PACKAGE IF DAMAGED

For more information, call ......................

IF DAMAGED

CAUTION!


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Lithium Batteries (UN3090, UN3091, UN3480, UN3481)(cont.)

Short Circuit Protection (cont.)

In addition to the statement discussed on page 6, U.S. domesticpackages of lithium metal batteries may be marked with a warningthat a package contains lithium batteries and that special proceduresmust be followed if the package is damaged. (This additional infor-mation is required if the package contains more than 24 cells or12 batteries.)

There are conditions under which a document should accompanythese shipments as well, stating that the package contains lithiumbatteries, must be handled with care and that a ammability hazardexists if the package is damaged. The document also should statethat special procedures are to be followed in the event the packageis damaged, to include inspection and repacking if necessary. Atelephone number for additional information is to be included. Thedocument is required for any shipment under the international regu-lations, and is also required for U.S. domestic shipments containingmore than 24 cells or more than 12 batteries. (This document, whenrequired, may be afxed to a UPS package in a document pouch.)

Small Lithium Ion BatteriesCareful packaging also applies to ship-ments of rechargeable lithium batteries. These batteries do not re-quire the marking that prohibits carriage aboard passenger aircraft.

Packagings used for lithium ion battery shipments need to berugged enough to keep the batteries from being crushed. For thisreason, international rules always require a package that is capableof being dropped 1.2 meters (approximately 4 feet) without break-ing open or damaging the batteries. This same requirement appliesin the U.S. when packages contain more than 24 lithium cells or morethan 12 lithium batteries. Strictly within the U.S., the gross packageweight must not exceed 30 kg (66 lb). Any international shipmentmust be restricted to a gross package weight of 10 kg (22 lb).

It is important to provide the necessary warnings on the outsideof a package containing lithium batteries. International regulations

require that any package of lithium ion batteries display a distinc-tive label (110 mm x 120 mm); the label may be reduced in sizefor smaller packages (74 mm x 105 mm):

U.S. domestic packages may be marked simply with a warni

a package contains lithium batteries and that special procedube followed if the package is damaged. (This marking is requthe package contains more than 24 cells or 12 batteries.)

There are conditions under which a document should accomthese shipments as well, stating that the package contains litbatteries, must be handled with care and that a ammabilityexists if the package is damaged. The document also shouldthat special procedures are to be followed in the event the pais damaged, to include inspection and repacking if necessartelephone number for additional information is to be includdocument is required for any shipment under the internation

lations, and is also required for U.S. domestic shipments comore than 24 cells or more than 12 batteries. (This documenrequired, may be afxed to a UPS package in a document p

Lithium Batteries Packed with or Contained in EquipmentIf you wish to ship a package containing a device that either haslithium batteries installed in it, or has its batteries packaged septhere are similar safety regulations covering these types of shipBy keeping the number of devices and batteries to a minimum, will simplify your compliance requirements. U.S. rules becomecomplex when packages contain over 5 kg net weight of batterior exceed a total of 24 cells or 12 batteries. (Guidance in this do

is restricted to smaller shipments. For packages that exceed 5 kweight of batteries, or quantities over 24 cells or 12 batteries, yoconsult the U.S. DOT Hazardous Materials Regulations,49 CFR 172.1Special Provision 188.)

Lithium Ion BatteryDO NOT LOAD OR TRANSPORT

PACKAGE IF DAMAGED


IF DAMAGED

CAUTION!


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Lithium Batteries (UN3090, UN3091, UN3480, UN3481)(cont.)

Lithium Metal Batteries Packed with Equipment or Contained in Equipment

Packed with Equipment The batteries, fully protected againstshort circuit, must be placed into a rugged inner package that fullycontains the batteries. The package should contain only the numberof batteries required to operate the device. (Up to two spare batter-ies may be packed, provided all the international requirements arefollowed.) Communication requirements must also be followed.

It is important to provide the necessary warnings on the outsideof a package containing lithium batteries. International regulationsrequire that any package of lithium metal batteries packed withequipment display a distinctive label (110 mm x 120 mm); the labelmay be reduced in size for smaller packages (74 mm x 105 mm):

The package must be accompanied by a document stating thatthe package contains lithium batteries, must be handled with careand that a ammability hazard exists if the package is damaged.The document also should state that special procedures are to befollowed in the event the package is damaged, to include inspec-tion and repacking if necessary. A telephone number for additionalinformation is to be included. (This document, when required, maybe afxed to a UPS package in a document pouch.)

Contained in EquipmentThe package is simplest to ship whenthere are no more than 4 cells or 2 batteries contained in the pack-age. If the package contains more than this number, the communi-

cation requirements discussed above must also be followed.

Lithium Ion Batteries Packed with Equipment or Contained

in Equipment Packed with EquipmentThe batteries, fully protected again

short circuit, must be placed into a rugged inner package thacontains the batteries. The package should contain only the of batteries required to operate the device. (Up to two spare ies may be packed, provided all the international requiremefollowed.) Communication requirements must also be follow

It is important to provide the necessary warnings on the outsof a package containing lithium batteries. International regulrequire that any package of lithium ion batteries packed withment display a distinctive label (110 mm x 120 mm); the lab

be reduced in size for smaller packages (74 mm x 105 mm):

The package must be accompanied by a document stating ththe package contains lithium batteries, must be handled withand that a ammability hazard exists if the package is damaThe document also should state that special procedures are tfollowed in the event the package is damaged, to include instion and repacking if necessary. A telephone number for addinformation is to be included. (This document, when requirebe afxed to a UPS package in a document pouch.)

Contained in Equipment The package is simplest to ship whthere are no more than 4 cells or 2 batteries contained in theage. If the package contains more than this number, the comcation requirements discussed above must also be followed

Lithium Metal BatteryDO NOT LOAD OR TRANSPORT

PACKAGE IF DAMAGED


IF DAMAGED

CAUTION!

Lithium Ion BatteryDO NOT LOAD OR TRANSPORT

PACKAGE IF DAMAGED


IF DAMAGED

CAUTION!


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Dry Batteries, Sealed, n.o.s.

These batteries are typically used for portable power applications, arehermetically sealed and generally use metals (other than lead) and/orcarbon as electrodes. They must meet all the requirements set forthin Special Provision 130 in 49 CFR 172.102, which includes preventionof the dangerous evolution of heat from short circuit or damage. UnderIATA, Special Provision A123 must be followed, which includes shortcircuit protection of exposed terminals and protection against acciden-tal activation of the battery.

Other BatteriesAlthough common dry cells (e.g., AA, C, D batteries) may not be regu-lated as hazardous materials, all batteries can cause res from short cir-

cuit if batteries and terminals are not protected. Each battery shipmentmust meet all the requirements set forth inSpecial Provision 130 in 49CFR 172.102, which includes prevention of the dangerous evolution ofheat from short circuit or damage. For air packages containing dry cellbatteries with a voltage (electrical potential) that exceeds nine volts,the words Not restricted must be marked on the package to indicatecompliance with the regulations. The equivalent requirement for IATAshipments is found inSection 4.4 of the IATA Dangerous Goods Regula-tions, as Special Provision A123 (see Fig. 5).

RECALLED OR RECYCLED BATTERIES

Never use air services to ship batteries recalled by the manufactfor safety reasons, as such shipments are prohibited by regulati(i.e.,IATA Dangerous Goods Regulations, Special Provision A1). Alsbatteries accumulated for recycling are not to be sent via air serThese services include UPS Next Day Air, UPS 2nd Day Air, UPSelect, International Express and International Expedited. UPSservice between Alaska, Hawaii or Puerto Rico and the continenis unavailable for either recalled or recycled batteries, as shipmin these lanes must travel by aircraft for at least one ight segm

ELECTRONIC ITEMS FOR REPAIR

Repair items, such as computers and cell phones, should be senwithout batteries.

While this document is designed to highlight safety practices for UPScustomers who pack and ship batteries, it does not replace the applicaregulations. For more information, consult the U.S. DOTs HazardousRegulations (49 CFR). You may also consult U.S. DOTs online informhttp://hazmat.dot.gov, or call the U.S. DOTs Hazardous Materials InfoCenter at 1-800-467-4922. International air shipments may additionallsubject to the Dangerous Goods Regulations of the International Air TransAssociation (IATA). For more information, seehttp://www.iata.org.

Cushioning

Blister Pack

Divider

Fig. 5Sample Packaging Dry Cell Batteries

Documents

Pack Ship Batteries