Lithium Batteries Transport and Packaging Instructions Multimodal approach 2025 MARCO OTTAVIANI
All rights reserved ©. No parts of this publication can be reproduced without the express editor’s authorization. Even though the editor and the author have paid maximum attention to ensure accuracy, they do not accept any responsibility in the case of errors or omissions. “Illustrations have been prepared in collaboration with AUTEC s.r.l and S.E.VAL. s.r.l. “ Copyright © 2025 This instruction manual has been prepared by Dr. M. Ottaviani. Publishing and delivery in partnership with Hyper srl via C.Bessarione 5b – 30173 Venice (Italy) tel.: +39 041976896 fax: +39 041985730 e-mail: info@hyperedizioni.com http://www.hyperedizioni.com Finished to print on June 2025
Table of Content Introduction 8 1. International Transport Regulations 9 1.1 How to use this instruction manual 11 1.2 Definitions 15 1.3 General requirements 18 1.3.1 Test requirements 18 1.3.1.1 Manual of Test and Criteria 18 1.3.1.2 Exemptions from the testing requirements 18 1.3.2 Manufacturing Quality Control Program 18 1.3.3 Protection from short circuit: 18 1.3.4 Damaged and Defective Batteries 19 1.3.5 Packages with both lithium batteries "packed with" and "contained in" equipment 20 1.4 Packaging 21 1.4.1 Table with Packaging Codes 22 1.5 Marking and Labelling 23 1.6 Documentation 26 1.7 Special Provisions 31 1.8 Packing instructions 32 1.9 Transport Mode specific requirements 33 1.9.1 Transporting Dangerous Goods from the United States into or through Canada 33 1.9.2 Marine International and DomesticTransport 34 1.9.2.1 IMDG Code 34 1.9.2.2 Marine Transport 34 1.9.2.3 Transporting Dangerous Goods from One Country through Canada to Another Country 34 1.9.3 Air International and Domestic Transport 34 1.9.4 IATA - Lithium metal batteries in checked baggage and carry-on baggage 35 1.9.5 IATA - Restrictions on packing lithium batteries with other dangerous goods 36 1.9.6 IATA - Packages in overpack 36 1.9.7 150 kg Gross Mass Exemption 36 1.9.8 500 kg Gross Mass Exemption 37 1.10 Training requirements 39 2. Shipping Modes Summary Sheets 41 List of Summary Sheets 42 2.1 LITHIUM METAL CELLS & BATTERIES (NEW) 43 2.1.1. LITHIUM METAL CELLS (including lithium alloy cells) – UN 3090 43 2.1.1_IA Fully regulated cells 44 2.1.1_IB Small partially excepted cells 46 2.1.2. LITHIUM METAL CELLS CONTAINED IN EQUIPMENT (including lithium alloy cells) - UN 3091 49 2.1.2_I Fully regulated cells 50 2.1.2_II Small excepted cells 52 2.1.3. LITHIUM METAL CELLS PACKED WITH EQUIPMENT (including lithium alloy cells) - UN 3091 55 2.1.3_I Fully regulated cells 56 2.1.3_II Small excepted cells 58 2.1.4. LITHIUM METAL BATTERIES (including lithium alloy batteries) – UN 3090 61 2.1.4_IA Fully regulated batteries 62 2.1.4_IB Small batteries partially excepted 64 Copyright © www.batteriestransport.org 5
2.1.5. LITHIUM METAL BATTERIES CONTAINED IN EQUIPMENT (including lithium alloy batteries) - UN 3091 67 2.1.5_I Fully regulated batteries 68 2.1.5_II Small batteries excepted 70 2.1.6 LITHIUM METAL BATTERIES PACKED WITH EQUIPMENT (including lithium alloy batteries) - UN 3091 73 2.1.6_I Fully regulated batteries 74 2.1.6_II Small batteries excepted 76 2.2 LITHIUM ION CELLS & BATTERIES (NEW) 75 2.2.1 LITHIUM ION CELLS (including lithium ion polymer cells) - UN 3480 79 2.2.1_IA Fully regulated cells 80 2.2.1_IB Small cells partially excepted 82 2.2.2 LITHIUM ION CELLS CONTAINED IN EQUIPMENT (including lithium ion polymer cells) - UN 3481 85 2.2.2_I Fully regulated cells 86 2.2.2_II Small cells excepted 88 2.2.3 LITHIUM ION CELLS PACKED WITH EQUIPMENT (including lithium ion polymer cells) - UN 3481 91 2.2.3_I Fully regulated cells 92 2.2.3_II Small cells excepted 94 2.2.4 LITHIUM ION BATTERIES (including lithium ion polymer batteries) - UN 3480 97 2.2.4_IA Fully regulated batteries 98 2.2.4_IB Small batteries partially excepted 100 2.2.5 LITHIUM ION BATTERIES CONTAINED IN EQUIPMENT 103 (including lithium (incl. lithium ion polymer cells) - UN 3481 2.2.5_I Fully regulated batteries 104 2.2.5_II Small batteries excepted 106 2.2.6 LITHIUM ION BATTERIES PACKED WITH EQUIPMENT 109 (including lithium ion polymer batteries) - UN 3481 2.2.6_I Fully regulated batteries 110 2.2.6_II Small batteries excepted 112 2.3 CELLS AND BATTERIES FOR DISPOSAL or RECYCLING 115 2.3.1 Fully regulated cells and batteries 116 2.3.2 Strong impact resistant out casing, mass of 12 kg or more 118 2.3.3 Small excepted cells and batteries 120 2.3.4 Cells and batteries contained in Equipment 122 2.4 CELLS & BATTERIES DAMAGED & DEFECTIVE 125 2.5 PRE-PRODUCTION PROTOTYPES & PRODUCTION RUNS ≤ 100 CELLS AND BATTERIES 129 6 Copyright © www.batteriestransport.org
Copyright © www.batteriestransport.org 7 Foreword When they are offered for transport, lithium batteries are regulated as Dangerous Goods by the United Nations Transport Organisation and other national transport authorities. This regulation is being permanently adapted to take into consideration the evolution of lithium battery technologies. Indeed, lithium metal battery markets have seen significant developments in the last twenty years. More recently, a similar evolution has been observed with the increasing role played by rechargeable Lithium-ion batteries in electrical and electronic equipment. Battery technology innovation and development helps an increasing number of technicians and engineers to design new equipment powered by portable sources of energy such as lithium batteries. The innovation capacity offered by lithium batteries opens the way to an increasing use of advanced rechargeable batteries in our modern society. The necessity for an increasing number of economic actors to respect the UN Dangerous Goods Regulation requires modern communication tools to inform the shippers of batteries about their duties and responsibilities when offering them for transport. The aim of this manual is to offer a simple and visual means to access the UN Regulation via a modern multimedia communication tool. The regulation is presented in a summarized format covering ground, air and maritime transportation modes. In a page opposite the various regulations, the packaging and labelling instructions are illustrated to facilitate the implementation of the transport regulation as well as the packaging and labelling requirements by the shipper of lithium batteries. The objective of the funding Associations is to offer access to the UN Transport Regulation to the largest number of interested parties in order to make them aware of their duties and responsibilities when shipping lithium metal or lithium ion batteries. We thank Dr. Marco Ottaviani for preparing this exhaustive document with the most updated information and Emanuele Fanizzi, the Editor, who has accepted to translate the information into modern multimedia tools accessible to the largest number of users. June 2025
Introduction The complexity of the International Dangerous Goods Transport Regulation for Lithium Batteries requires an increasing attention from those who are shipping these batteries. Lithium batteries are classified as “Class 9” Dangerous Goods in accordance with United Nations Recommendations on the Transport of Dangerous Goods Model Regulations The regulations may frequently change anyway depending on the transport model utilized. This Manual is aimed at delivering basic information to those who are not yet familiar with these International Dangerous Goods Transport Regulations. The manual is divided into two parts. Part 1 is summarizing the main regulation requirements for road, sea and air transport. Part 2 contains 30 Summary Sheets where the different transport modes requirements are summarized in one page. On the opposite page, an illustration of the packaging instructions is offered to the reader and presented with illustrative examples to guide the reader. The Manual is organised according to the UN Number of lithium batteries, considering "new" and "waste" batteries, the “quantities” of batteries that are shipped, starting from the largest “fully regulated” and ending with the small “excepted” quantities. In case of “used” batteries they have to be evaluated individually, as well as “damaged or defective” batteries. This manual is only a guide to assist the reader in preparing lithium batteries shipments for transportation by road, sea and air. It doesn’t replace any of the regulations manual that are applicable to the shipment of lithium batteries. If you have any comment on the content of this Manual, we would be pleased to take them into consideration for any further improvement of its content and its practical use. 8 Copyright © www.batteriestransport.org
1. International Transport Regulations Copyright © www.batteriestransport.org 9 UN Model Regulations The Recommendations concerning the transport of all type of dangerous goods have been developed by the United Nations Economic and Social Council’s Committee of Experts on the Transport of Dangerous Goods with the aim to ensure the safety of people, property and the environment. They are applicable to all modes of transport and are addressed to governments and international organizations concerned with the regulation of the transport of dangerous goods. They are published in the “Recommendations on the Transport of Dangerous Goods—Model Regulations”. Edition applicable → 23rd revised edition UN Manual of Tests and Criteria UN Manual of Test and Criteria are developed by the United Nations Economic and Social Council’s Committee of Experts on the Transport of Dangerous Goods and published as a separate manual in the “Recommendations on the Transport of Dangerous Goods— Manual of Tests and Criteria”. Edition applicable → Revision 8 Road Transportation of Dangerous Goods Act, 1992 - S.C. 1992, c. 34 Assented to 1992-06-23 An Act to promote public safety in the transportation of dangerous goods Edition applicable → 2024-05-15 Use of 49 CFR for Non-Regulated Dangerous Goods When a substance is regulated in the United States by 49 CFR but is not regulated in Canada by these Regulations, a person may transport the substance between Canada and the United States by road vehicle or railway vehicle in accordance with all or part of 49 CFR. Marine - IMDG Code Transportation of Dangerous Goods Act, 1992 - S.C. 1992, c. 34 Assented to 1992-06-23 An Act to promote public safety in the transportation of dangerous goods Edition applicable → 2024-05-15 International Maritime Dangerous Goods (IMDG) Code is prepared by International Maritime Organization - IMO and is consistent with the United Nations “Recommendations on the Transport of Dangerous Goods—Model Regulations”. IMDG Code harmonizes the practices and procedures followed in the carriage of dangerous goods by sea and ensures compliance with the mandatory provisions of the SOLAS Convention (International Convention for the Safety of Life at Sea) and of Annex III of MARPOL (International Convention for the Prevention of Pollution from Ships). Edition applicable → IMDG Code 41-22 On a voluntarily base → IMDG Code 42-24 IATA Air - ICAO TI Transportation of Dangerous Goods Act, 1992 - S.C. 1992, c. 34 Assented to 1992-06-23 An Act to promote public safety in the transportation of dangerous goods Edition applicable → 2024-05-15 The International Civil Aviation Organization (ICAO) develops the regulations for the safe transport of dangerous goods by air by any aircraft (including both internal and external carriage) on the basis of the Recommendations on the Transport of Dangerous Goods—Model Regulations. The ICAO regulations are codified in Annex 18 to the Convention on International Civil Aviation and in its Technical Instructions for the Safe Transport of Dangerous Goods by Air (ICAO – TI’s) and are recognized as the sole authentic legal source material in the air transport of dangerous goods. Edition applicable → ICAO Technical Instruction 2025-2026 edition The International Air Transport Association (IATA) publishes the Dangerous Goods Regulations (IATA DGR) based on the requirements of Annex 18 to the Convention on International Civil Aviation and the associated Technical Instructions for the Safe Transport of Dangerous Goods by Air, published by ICAO. IATA DGR constitute a manual of industry carrier regulations to be followed by all IATA Member airlines. There are certain differences between the IATA and ICAO regulations which stem from operational considerations and result in a regulatory regime which is necessarily more restrictive than the ICAO requirements. The IATA Regulations also incorporate additional material of practical assistance to users. Edition applicable → IATA Dangerous Goods Regulations 2025 – 66th Edition
Copyright © www.batteriestransport.org 10 Periods of applications of International Transport Regulations This edition refers to the year 2025
1.1 How to use this instruction manual This manual is designed to provide a quick and effective guide to personnel who needs to prepare a shipment of lithium cells and batteries, either new or waste, by road, maritime and air transport modes. It consists of two parts. The first part describes and summarizes the regulatory aspects applicable to the transport of lithium batteries, introducing the basic concepts of the transport of dangerous goods, the duties they impose on producers, distributors and users; it also provides a guide to using the manual in order to give to the user the necessary information. In the second part Summary Sheets are provided for the three modes of transport. This information is condensed into one page. On the opposite page, images and flow charts illustrating how to perform in practice the packaging requirements, guiding the user step by step to prepare the correct shipment, in accordance with the regulation. The battery manufacturers have specific compliance obligations during production and only batteries successfully tested in accordance with the UN Manual of Tests and Criteria can be transported and placed on the market. The United Nations Manual of Tests and Criteria, updated periodically, imposes several requirements to be observed by shippers of Lithium Metal and Lithium Ion Batteries. Producers, distributors, users, waste managers, recyclers, all those who ship lithium batteries new or waste or even damaged and defective, or that forward them, with or without re-packing, have the obligation to comply with the applicable regulations depending on the different modes: road, maritime and air. It is therefore necessary to know, for each shipment, how to prepare the batteries, which packaging is allowed, how to mark and label packages and which documents to prepare to accompany the shipment. In additions shippers must take into account specific requirements of each transport mode. The provisions applicable in the various transport modes may differ because they are adapted to ensure maximum safety during transport. This means that regulators have introduced special provisions, restrictions and limitations, or other exemptions and exclusions, with the result of making even more complex the regulatory framework for the transport of Lithium Batteries. This manual will propose a decision path that, in six steps, allows users to access the information needed to prepare lithium batteries for transport with the appropriate packaging shipping papers, markings, and labels. These six steps are schematically presented, for new batteries, in the next flowchart. • Cell or battery Cell : a single encased electrochemical unit (one positive and one negative electrode) which exhibits a voltage differential across its two terminals. Battery: two or more cells which are electrically connected together. Step 1 Lithium Metal or Lithium Ion There are many types of lithium batteries which differ by the nature and composition of the electrodes materials, the substances present in the electrolyte and the capacity to convert chemical energy into electricity. For the purposes of dangerous goods transport regulations, however, lithium batteries classification has been reduced to two groups: lithium metal and lithium ion. Copyright © www.batteriestransport.org 11
Lithium metal batteries, also including lithium metal alloys, consists of cells and batteries containing lithium in the metallic form. They are used to power small consumer electrical appliances and devices such as watches, cameras, calculators etc. They can also be assembled into large batteries e.g. in the oil rig drilling heads. Lithium ion batteries including lithium ion polymer battery consists of cells and batteries containing lithium in the ionic form. They are used in consumer electronics, such as mobile phones, laptops, tablets and MP3 players. In the larger sizes they are being used to power cordless power tools, e-bikes, electric or hybrid electric vehicles, energy storage and many other industrial applications. The two groups of Lithium Batteries, the Lithium-Metal and the Lithium-Ion show different hazards and therefore are assigned to two different entries in the UN Dangerous Goods Regulations. The Regulations take also into consideration the transport and packaging requirements of such batteries installed in equipment or packed with equipment: UN 3090 LITHIUM METAL BATTERIES UN 3091 LITHIUM METAL BATTERIES CONTAINED IN EQUIPMENT UN 3091 LITHIUM METAL BATTERIES PACKED WITH EQUIPMENT UN 3480 LITHIUM ION BATTERIES UN 3481 LITHIUM ION BATTERIES CONTAINED IN EQUIPMENT UN 3481 LITHIUM ION BATTERIES PACKED WITH EQUIPMENT 12 Copyright © www.batteriestransport.org
Step 2 Evaluate and confirm – The content in grams of lithium in the lithium metal cells and batteries – The Wh rating of lithium ion cells and batteries Step 3 Decide if you ship: – Cells or batteries as batteries, – Cells and batteries contained in equipment or – Cells and batteries packed with equipment Step 4 Go to chapter § 2 of this manual and following the chart with the characteristics of your batteries, identify your transport requirements in accordance with the 15 groups listed. Step 5 Go to the first sheet of the identified group and according to the Flow Chart, using the data collected, identify the specific Summary Sheet related to your transport requirements for the given types of batteries to be shipped. Step 6 LEFT page of Summary Sheet: Use the information of the Summary Sheet from top to bottom, the relevant provisions have been included in the Summary Sheet according to a logical and practical path. The differences in road, marine and air transport and packaging requirements have been identified by different background colors and highlighted step by step. A white background is used where the provisions are applicable to more than one transport mode. The orange background applies to road transportation, pink applies to marine transportation and blue applies to air transportation. On the LEFT page, the Summary Sheet contains the following information: Where applicable, a) UN Number, b) Proper shipping Name, c) Class d) Packing Group e) Hazard label f) Prerequisite, conformity to the general requirements g) Specific requirements h) Exemption conditions i) Packing instructions j) Authorized packagings k) Quantity and weight limits l) Provisions applicable to road transportation (i.e. tunnel code, transport category, road transport exemptions) m) Marking and labelling on packages n) Overpack labels and markings o) Specific transport document required p) Instructions to personnel RIGHT page of Summary Sheet: On the opposite page (to the right), images show an example of how to practically prepare packaging for shipment: how to protect cells and batteries from short-circuit, verify and use internal and external packaging, labelling and marking of packages. Copyright © www.batteriestransport.org 13
Overpack OVERPACK + same labels as above OVERPACK + same labels as above OVERPACK + same labels as above Restriction: see § 1.9.3 Documents Transport document MDGF Shipper’s Declaration Example of the Six Steps Method: Lithium metal cell, with Li content 4.5 g/cell, packed as batteries, transported by road Step Actions and data Key words 1 New product (not waste) From the Product Data Sheet: Lithium Metal - New - Lithium Metal - Cell 2 From the Product Data Sheet: Lithium metal content 4.5 g/cell - 4.5 g/cell 3 Packed as batteries - As Batteries 4 Go to § 2 “List of Summary Sheets” and follow the key words: New→Lithium metal →Cells →As Batteries Obtain→ § 2.1.1 LITHIUM METAL CELLS - § 2.1.1 5 Go to § 2.1.1 and follow the flow chart for “road transportation” →according the lithium content 4.5 g/cell, your Summary Sheet is →2.1.1_IA - § 2.1.1_IA 6 →Now apply it, following the provision for Road (the orange column) and the one in white background, which are common to other transport modes End of the search CANADA Transportation of Dangerous Goods Regulation Shipping Modes Summary Sheets 44 List of Summary Sheets 2.1.1 LITHIUM METAL CELLS As Batteries UN 3090 2.1.1_IA Fully regulated cells 2.1.1_IB Small cells partially excepted 2.1.2 LITHIUM METAL CELLS CONTAINED IN EQUIPMENT Cells Contained IN UN 3091 2.1.2_I Fully regulated cells Equipment 2.1.2_II Small cells excepted 2.1.3 LITHIUM METAL CELLS PACKED WITH EQUIPMENT Lithium Packed WITH UN 3091 2.1.3_I Fully regulated cells Metal Equipment 2.1.3_II Small cells excepted Including Lithium 2.1.4 LITHIUM METAL BATTERIES Metal As Batteries UN 3090 2.1.4_IA Fully regulated batteries Alloy 2.1.4_IB Small batteries partially excepted 2.1.5 LITHIUM METAL BATTERIES CONTAINED IN EQUIPMENT Batteries Contained IN UN 3091 2.1.5_I Fully regulated batteries Equipment 2.1.5_II Small batteries excepted 2.1.6 LITHIUM METAL BATTERIES PACKED WITH EQUIPMENT Packed WITH UN 3091 2.1.6_I Fully regulated batteries Equipment 2.1.6_II Small batteries excepted New 2.2.1 LITHIUM ION CELLS As Batteries UN 3480 2.2.1_IA Fully regulated cells 2.2.1_IB Small cells partially excepted 2.2.2 LITHIUM ION CELLS CONTAINED IN EQUIPMENT Cells Contained IN UN 3481 2.2.2_I Fully regulated cells Equipment 2.2.2_II Small cells excepted 2.2.3 LITHIUM ION CELLS PACKED WITH EQUIPMENT Lithium Packed WITH UN 3481 2.2.3_I Fully regulated cells Ion Equipment 2.2.3_II Small cells excepted Including Lithium Ion 2.2.4 LITHIUM ION BATTERIES polymer As Batteries UN 3480 2.2.4_IA Fully regulated batteries 2.2.4_IB Small batteries partially excepted 2.2.5 LITHIUM ION BATTERIES CONTAINED IN EQUIPMENT Batteries Contained IN UN 3481 2.2.5_I Fully regulated batteries Equipment 2.2.5_II Small batteries excepted 2.2.6 LITHIUM ION BATTERIES PACKED WITH EQUIPMENT Packed WITH UN 3481 2.2.6_I Fully regulated batteries Equipment 2.2.6_II Small batteries excepted 2.3 CELLS AND BATTERIES FOR DISPOSAL OR RECYCLING Waste Mix or alone or Lithiummetal, lithium ion, 2.3.1 Fully regulated cells and batteries In Equipment 2.3.2 Strong impact resistant out casing, mass of 12 kg or more 2.3.3 Small excepted cells and batteries 2.3.4 Cells and batteries contained in Equipment Damaged & Lithiummetal, lithium ion, cells and batteries 2.4 CELLS AND BATTERIES DAMAGED & DEFECTIVE Defective 2.4.1 Cells and batteries not critical Pre-production Prototypes & Lithiummetal, lithium ion, cells and batteries 2.5 PRE-PRODUCTION PROTOTYPES & PRODUCTION RUNS CELLS AND BATTERIES Produc p t i i e o c n e run CANADA Transportation of Dangerous Goods Regulation 45 2.1 LITHIUM METAL CELLS & BATTERIES (NEW) 2.1.1 LITHIUM METAL CELLS (including lithium alloy cells) Flow Chart UN 3090 Lithium Metal Cell: primary (non-rechargeable) cell that have lithium metal or lithium compounds as an anode. Road, Marine SP 34/188 Air PI 968, Section IB Summary Sheet § 2.1.1_IB Small cells partially excepted NO Lithium metal content (g/cell) Li YES Road, Marine P903 - LP903 Air PI 968, Section IA Summary Sheet § 2.1.1_IA Fully regulated cells CANADA Transportation of Dangerous Goods Regulation Copyright © Recharge and Hyper – Shipping Modes Summary Sheets – New Lithium Ion Cells Packages Minimum dimensions: 120 110 mm Overpack OVERPACK + same labels as above OVERPACK + same labels as above OVERPACK + same labels as above Restriction: see § 1.9.3 Documents Transport document MDGF Shipper’s Declaration 2.1.1_IA LITHIUM METAL CELLS (including lithium alloy cells) Fully regulated cells UN 3090 Applies to: Lithium metal cells with a lithium metal content in excess of 1 g/cell Air Only: Lithium metal cells with a lithium metal content not exceeding 1 g/cell transported in quantities that exceed the allowance permitted in § 2.1.1_IB UN No., Proper Shipping Name UN 3090, LITHIUM METAL BATTERIES Class 9 Packing Group Not assigned Hazard Label Labels must be in the form of a square set at an angle of 45° (diamond-shaped) with minimum dimensions of 100 mm by 100 mm; except for air transport mode, labels dimensions may be reduced not less then 30mm by 30mm on small packages. They must have a line 5 mm inside the edge and running parallel with it. Prerequisite Cells must meet the General Requirements of § 1.3 in particular the test requirements Specific Requirements Each cell incorporates a safety venting device or is designed to preclude a violent rupture under normal conditions of carriage; Each cell is equipped with an effective means of preventing external short circuits Transport mode Road Marine Air Passenger Aircraft Cargo Packing instructions P903 P903 PI 968 section IA Cells must be protected against short circuit, including protection against contact with conductive materials within the same packaging which could cause a sh rt circuit. Cells must be packed so that are protected against damage caused by the movement or placement of the cells within the packaging Use only approved packaging conforming to Packing Group II performance level. Forbidden lithium metal cells must be placed in inner packagings that completely enclose the cell, then placed in an outer packaging. complete package must be approved Packing Group II performance level Restriction: see § 1.9.3 Packagings Drums (1A2, 1B2, 1N2, 1H2, 1D, 1G); Boxes (4A, 4B, 4N, 4C1, 4C2, 4D, 4F, 4G, 4H1, 4H2) Jerricans (3A2, 3B2, 3H2). Drums (1A2, 1B2, 1N2, 1H2, 1D, 1G); Boxes (4A, 4B, 4N, 4C1, 4C2, 4D, 4F, 4G, 4H2) Jerricans (3A2, 3B2, 3H2). Cell kg (gross) with a strong, impact resistant outer casing Not required UN approved packagings for cells, or assemblies of such cells, when packed in strong outer packagings or protective enclosures (i.g. fully enclosed or wooden slatted crates) Allowed transport on Pallets or other handling devices. Cells must be secured to prevent inadvertent movement, and the terminals must not support the weight of other superimposed elements Outer packagings or protective enclosures approved by the appropriate authority of the State of origin. A copy of the document of approval must accompany the consignment. Large Packaging LP903 LP903 Rigid Large packagings, conforming to the packing group II performance level, are authorized for a single battery.: steel (50A); aluminium (50B); metal other than steel or aluminium (50N); rigid plastics (50H); natural wood (50C); plywood (50D); 14 Copyright © www.batteriestransport.org
1.2 Definitions “ADR” means the Agreement concerning the International Carriage of Dangerous Goods by Road (European region) “Approved packagings” means packagings manufactured under a quality assurance programme, which satisfies the competent authority, conform to the prototype which has passed specific tests. “Automotive battery” means any battery used for automotive starter, lighting or ignition power; “Industrial battery” means any battery designed for industrial or professional uses or used in any type of electric vehicle “Bag” means flexible container made of paper, plastic film, textiles, woven material or other suitable materials. “Battery” means two or more cells which are electrically connected together and fitted with devices necessary for use, for example, case, terminals, marking and protective devices. A single cell lithium battery is considered a "cell”. "Battery pack" means any set of primary or rechargeable cells or batteries that are connected together and/or encapsulated within an outer casing so as to form a complete unit that the end-user is not intended to split up or open. Note: “battery packs”, “modules” or “battery assemblies” having the primary function of providing a source of power to another piece of equipment, for the purposes of this manual are treated as batteries. “Box” means outer packaging with complete rectangular or polygonal faces, made of metal, wood, plywood, reconstituted wood, fibreboard, plastic or other suitable material. "Button cell" means any small round portable battery or accumulator whose diameter is greater than its height. “Cargo aircraft” means an aircraft, other than a passenger carrying aircraft, that is carrying goods or property. “Carrier” means a person who, whether or not for hire or reward, has possession of dangerous goods while they are in transport. “Cell” means a single encased electrochemical unit (one positive and one negative electrode) which exhibits a voltage differential across its two terminals. Note: Under the International Dangerous Goods Regulations and the UN Manual of Tests and Criteria, to the extent the encased electrochemical unit meets the definition of “cell”, it is a “cell”, not a “battery”, regardless of whether the unit is termed a “battery” or a “single cell battery” outside of regulations and the UN Manual of Tests and Criteria . “Certification safety mark” means a design, symbol, device, letter, word, number or abbreviation that is displayed on a means of containment or means of transport to indicate compliance with a safety standard. “Combination packaging” means a container consisting of one or more inner packagings contained in an outer packaging for transport. "Consignee" means any person, organization or government which is entitled to take delivery of a consignment “Consignment” means a quantity of dangerous goods transported at the same time in one or more means of containment from one consignor at one location to one consignee at another location "Consignor" means a person in Canada who (a) is named in a shipping document as the consignor; (b) imports or who will import dangerous goods into Canada; or (c) if paragraphs (a) and (b) do not apply, has possession of dangerous goods immediately before they are in transport. Copyright © www.batteriestransport.org 15
“Consolidation bin” means a bin that is used in a road vehicle (a) to secure one or more small means of containment so that, under normal conditions of transport, they will not shift in a way that might compromise their integrity; and (b) to allow small means of containment to be added or removed during transport “Crate” means rigid outer container with incomplete surfaces. “Dangerous goods safety mark” means a label, placard, orange panel, sign, mark, letter, word, number or abbreviation that is used to identify dangerous goods and to show the nature of the danger posed by them “Drum” means a flat-ended or convex-ended cylindrical means of containment made of metal, fibreboard, plastic or other similar material, with a maximum capacity of 450 L, or for a drum made of plywood, a maximum capacity of 250 L. This definition includes means of containment of other shapes such as pail-shaped or round with a tapered neck, but does not include a wood barrel or jerrican (that is, a means of containment of rectangular or polygonal cross-section) “IATA DGR” means the International Air Transport Association - Dangerous Goods Regulation “ICAO” means International Civil Aviation Organization. "IMDG Code" means the International Maritime Dangerous Goods Code, “Inner packaging” means a container in direct contact with its contents, for which an outer packaging is required for transport. “Jerrican” means a metal or plastic container of rectangular or polygonal cross-section “Large means of containment” means a means of containment with a capacity greater than 450 L “Lithium metal batteries” have lithium metal or lithium compounds as an anode. The most common type of lithium cell used in consumer applications are primary cells using metallic lithium as anode and manganese dioxide as cathode, with a salt of lithium dissolved in an organic solvent. “Lithium-ion batteries” (sometimes abbreviated Li-ion batteries) are a type of secondary (rechargeable) battery commonly used in consumer electronics. Also included within lithium-ion batteries are lithium polymer batteries. “Lithium battery”: in this manual the term "lithium battery" covers all cells and batteries containing lithium in any form. “Lithium content” means the mass of lithium in the anode of a lithium metal or lithium alloy cell "Manual of Tests and Criteria" mean the Recommendations on the Transport of Dangerous Goods, Manual of Tests and Criteria, published by the United Nations. “Offer for transport” means, for dangerous goods not in transport, to select or allow the selection of a carrier to transport the dangerous goods, to prepare or allow the preparation of the dangerous goods so that a carrier can take possession of them for transport or to allow a carrier to take possession of the dangerous goods for transport “Outer packaging” means a container that is not in direct contact with the dangerous goods, which contains one or more inner packaging or an inner receptacle. “Overpack” means an enclosure that is used by a single consignor to consolidate one or more small means of containment for ease of handling but that is not a minimum required means of containment. This definition does not include a large means of containment or a unit load device, as defined in the ICAO Technical Instructions, that is intended for transport by aircraft. "Package" means the complete product of the packing operation, consisting of the packaging and its contents prepared for dispatch. 16 Copyright © www.batteriestransport.org
“Packing group” means a group in which dangerous goods are included based on the inherent danger of the dangerous goods; Packing Group I indicates great danger, Packing Group II indicates medium danger and Packing Group III indicates minor danger “Safety mark” includes a design, symbol, device, sign, label, placard, letter, word, number or abbreviation, or any combination of these things, that is to be displayed (a) on dangerous goods, on means of containment or transport used in handling, offering for transport or transporting dangerous goods, or at facilities used in those activities; and (b) to show the nature of the danger or to indicate compliance with the safety standards prescribed for the means of containment or transport or the facilities. "Shipper” has the same meaning of consignor. “Shipping document” means a document that relates to dangerous goods that are being handled, offered for transport or transported and that contains the information required by Part 3 (Documentation) relating to the goods but does not include an electronic record. "Single cell battery" as defined in Part III, sub-section 38.3.2.3 of the UN Manual of Tests and Criteria is considered a “cell” and must be transported according to the requirements for “cells”. “Single packaging” means a container, other than a combination packaging. “Small means of containment” means a means of containment with a capacity less than or equal to 450 L. “Substance” includes an article “Technical name” means the chemical name or another name currently used in a scientific or technical handbook, journal or text but does not include a trade name. “UN Model Regulations" means the UN Recommendations on the Transport of Dangerous Goods Model Regulation published by the United Nations. “UN standardized means of containment” means a means of containment that meets the requirements set out in section 5.6 of Part 5 (Means of Containment) “UN Standardized container” means a UN standardized means of containment, as defined in the TDG regulations, but for the purpose of this standard having a maximum capacity less than or equal to 450 L. "Wastes" means substances, solutions, mixtures or articles for which no direct use is envisaged but which are transported for reprocessing, dumping, elimination by incineration or other methods of disposal. “Watt-hour or Wh” the electrical energy developed by a power of 1 watt (W) during 1 hour (h) and expressed as watt-hour (Wh). Words “shall", "should" and "may": in the International Transport Regulations, the words "shall", "should" and "may" mean that the relevant provisions are "mandatory", "recommendatory" and "optional", respectively. In these Regulations, (a) “must” is imperative and “may” is permissive; (b) the words “on”, “in” or “by” are synonymous when they are associated with the defined terms road vehicle, railway vehicle, vessel or aircraft; Copyright © www.batteriestransport.org 17
1.3 General requirements 1.3.1 Test requirements 1.3.1.1 Manual of test and Criteria Each cell or battery is of the type proved to meet the requirements of each test of the Manual of Tests and Criteria, Part III, sub-section 38.3. Batteries shall be of a type proved to meet the testing requirements of the Manual of Tests and Criteria, part III, sub-section 38.3, irrespective of whether the cells of which they are composed are of a tested type. Due to copyright restriction, this manual cannot contain the text of Manual of Tests and Criteria, however, as a user, you can consult it at the following website: https://unece.org/transport/dangerous-goods/rev7-files 1.3.1.2 Exemptions from the testing requirements: Exemptions under the Road and Marine Transport Modes (special provision 123) The testing requirements in sub-section 38.3 of the Manual of Tests and Criteria do not apply to • Low production runs consisting of not more than 100 cells and batteries. • Pre-production prototypes of lithium cells and batteries when these prototypes are transported for testing. They have to be packed in accordance to Packing Instruction P910 Exemptions under the Air Transport Mode (special provision A88) Small but significant differences exist in air transport: • Low production runs consisting of not more than 100 cells and batteries per year. • Transport aboard Cargo aircraft must be approved by the appropriate authority of the State of origin, even if all requirements of Packing Instruction 910 are met. 1.3.2 Manufacturing Quality Control Program Cells and batteries shall be manufactured under a quality management programme that includes: • description of the organizational structure; • responsibilities of personnel with regard to design and product quality; • inspection and test instruction; • quality control instruction; • quality assurance instruction, • process operation instructions; • process controls, including relevant activities to prevent and detect internal short circuit failure during manufacture of cells; • quality records, such as inspection reports, test data, calibration data and certificates; • test data shall be kept and made available to the competent authority upon request; • management reviews under quality management programme; • documents control and revision; • a means for control of cells or batteries that are not conforming to the type tested • training programmes and qualification procedures for relevant personnel; and • procedures to ensure that there is no damage to the final product. NOTE: In house quality management programmes may be accepted. Third party certification is not required, but the procedures listed above shall be properly recorded and traceable. A copy of the quality management programme shall be made available to the competent authority upon request. 18 Copyright © www.batteriestransport.org
Due to copyright restriction, this manual cannot contain the text of the Manufacturing Quality Control Programme however, as a user, you can consult § 2.9.4 of the UN Model Regulation at the following website: https://unece.org/transport/dangerous-goods/un-model-regulations-rev-22 1.3.3 Protection from short circuit Cells and batteries must be protected so as to prevent short circuits. This includes protection against contact with conductive materials within the same packaging that could lead to a short circuit. Examples of protection against short circuits include, but are not limited to: • individual protection of the battery terminals, • inner packaging to prevent contact between cells and batteries, • batteries with recessed terminals designed to protect against short circuits, or • the use of an electrically non-conductive and non-combustible cushioning material to fill empty space between the cells or batteries in the packaging. 1.3.4 Damaged and Defective Batteries Damaged lithium batteries mean in particular, but are not limited to: - Cells or batteries identified as being defective for safety reasons; - Cells or batteries that have leaked or vented; - Cells or batteries that cannot be diagnosed prior to carriage; or - Cells or batteries that have sustained physical or mechanical damage. In assessing a cell or battery as damaged or defective, an assessment or evaluation shall be performed based on safety criteria from the cell, battery or product manufacturer or by a technical expert with knowledge of the cell’s or battery’s safety features. An assessment or evaluation may include, but is not limited to, the following criteria: (a) Acute hazard, such as gas, fire, or electrolyte leaking; (b) The use or misuse of the cell or battery; (c) Signs of physical damage, such as deformation to cell or battery casing, or colours on the casing; (d) External and internal short circuit protection, such as voltage or isolation measures; (e) The condition of the cell or battery safety features; or (f) Damage to any internal safety components, such as the battery management system. Transport of damaged and defective batteries is regulated as follow: Road and Marine Cells and batteries “not critical” (not liable to dangerously react during transport): Permitted according Special Provision 137 (road) and 376 (marine) Packing Instructions P908 and LP904 Air Forbidden to transport by aircraft. Cells and batteries “not critical”: NOT liable to dangerously react during transport The packing procedures require approved packagings of packing group II performance level. Packages shall be marked “DAMAGED/DEFECTIVE LITHIUM-ION BATTERIES” or “DAMAGED/DEFECTIVE LITHIUM METAL BATTERIES”, as applicable. Cells or batteries shall be protected against short circuit. Copyright © www.batteriestransport.org 19
Each damaged or defective cell or battery or equipment containing such cells or batteries shall be individually packed in inner packaging and placed inside an outer packaging. A cell or battery with a net mass of more than 30 kg shall be limited to one cell or battery per outer packaging. Each inner packaging shall be surrounded by sufficient non-combustible and electrically nonconductive thermal insulation material to protect against a dangerous evolution of heat. Non combustibility shall be assessed according to a standard recognized in the country where the packaging is designed or manufactured. Appropriate measures shall be taken to minimize the effects of vibrations and shocks, prevent movement of the cells or batteries within the package that may lead to further damage and a dangerous condition during carriage. Cushioning material that is non-combustible and electrically non-conductive may also be used to meet this requirement. The inner packaging or outer packaging shall be leak-proof to prevent the potential release of electrolyte. For leaking cells or batteries, sufficient inert absorbent material shall be added to the inner or outer packaging to absorb any release of electrolyte. Cells and batteries LIABLE TO DANGEROUSLY REACT during transport It is forbidden to transport lithium cells and batteries that are damaged or defective and that under normal conditions of transport, are liable to rapidly disassemble, dangerously react, produce a flame or a dangerous evolution of heat or a dangerous emission of toxic, corrosive or flammable gases or vapours 1.3.5 Packages containing a combination of lithium batteries "packed with" and "contained in" equipment IMDG SP390 - When a package contains a combination of lithium batteries contained in equipment and lithium batteries packed with equipment, the following requirements apply for the purposes of package marking and documentation: (a) the package shall be marked “UN 3091” or “UN 3481”, as appropriate. If a package contains both lithium ion batteries and lithium metal batteries packed with and contained in equipment, the package shall be marked as required for both battery types. However, button cell batteries installed in equipment (including circuit boards) need not be considered; (b) the transport document shall indicate “UN 3091 LITHIUM METAL BATTERIES PACKED WITH EQUIPMENT” or “UN 3481 LITHIUM ION BATTERIES PACKED WITH EQUIPMENT”, as appropriate. If a package contains both lithium metal batteries and lithium ion batteries packed with and contained in equipment, then the transport document shall indicate both “UN 3091 LITHIUM METAL BATTERIES PACKED WITH EQUIPMENT” and “UN 3481 LITHIUM ION BATTERIES PACKED WITH EQUIPMENT”. IATA A181 - Air transport regulation clarifies the requirements for this combination of lithium batteries packed with equipment and lithium batteries contained in equipment in the same package: - the package must be marked UN 3091 Lithium metal batteries packed with equipment, or UN 3481 Lithium ion batteries packed with equipment as appropriate. - all applicable parts of both packing instructions must be met. - button cell batteries installed in equipment (including circuit boards) need not be considered. 20 Copyright © www.batteriestransport.org
- the total weight of lithium batteries contained in any package must not exceed the limits for passenger aircraft or cargo aircraft, as applicable; - the Shipper's Declaration must indicate UN 3091 Lithium metal batteries packed with equipment or UN 3481 Lithium ion batteries packed with equipment, as appropriate. - if a package contains both lithium ion batteries and lithium metal batteries packed with and contained in equipment, the package must be marked as required for both battery types and the dangerous goods transport document must indicate both UN 3091 Lithium metal batteries packed with equipment and UN 3481 Lithium ion batteries packed with equipment. 1.4 Packaging Dangerous goods shall be packed in good quality packagings. Packagings shall be strong enough to withstand the shocks and loadings normally encountered during carriage, including trans-shipment between transport units and between transport units and warehouses. Packagings shall be constructed and closed so as to prevent any loss of contents when prepared for transport which might be caused under normal conditions of transport, by vibration, or by changes in temperature, humidity or pressure No dangerous residue shall adhere to the outside of packagings during carriage. “Overpack” means an enclosure that is used by a single consignor to consolidate one or more small means of containment for ease of handling but that is not a minimum required means of containment (see definition in § 1.2). Examples of Overpack: 1. A loading tray such as a pallet, on which several packages are placed or stacked and secured by a plastics strip, shrink or stretch wrapping or other appropriate means; or 2. An outer protective packaging such as a box or a crate; "Package" means the complete product of the packing operation, consisting of the packaging and its contents prepared for dispatch. Dangerous goods shall not be packed together in the same outer packaging or in large packagings, with dangerous or other goods if they react dangerously with each other and cause: (a) combustion or evolution of considerable heat; (b) evolution of flammable, asphyxiant, oxidizing or toxic gases; (c) the formation of corrosive substances; or (d) the formation of unstable substances. Before being filled and handed over for carriage, every packaging, including IBCs and large packagings, shall be checked to be free from corrosion, contamination or other defects Any packaging which shows signs of weakening, with reference to the approved prototype shall no longer be used or shall be refurbished so that it can pass the tests required for the prototype. Plastic packagings For plastics drums and jerricans, rigid plastics IBCs and composite IBCs with plastics inner receptacles, unless otherwise approved by the competent authority, the period of use permitted for the carriage of dangerous substances shall be five years from the date of manufacture of the receptacles, except where a shorter period of use is prescribed because of the nature of the substance to be carried. Approved packagings: The packs can be used must have passed specific tests and testing conform to the prototype tested. Copyright © www.batteriestransport.org 21
Packagings shall be manufactured, reconditioned and tested under a quality assurance programme which satisfies the competent authority. Shall bear markings which are durable, legible and readily visible, constituted by a sequence of symbols, letters and numbers, i.e.: Not approved packagings: Where packagings which need not meet the requirements of 4.1.1.3 (e.g. crates, pallets) are authorized in a packing instruction or the special provisions, they are not subject to the mass or volume limits generally applicable to packagings (400 kg or 450 L) conforming to the requirements of Chapter 6.1, unless otherwise indicated in the relevant packing instruction or special provision. 1.4.1 Table with Packaging Codes Kind Material Category Code A. Steel removable head 1A2 B. Aluminium removable head 1B2 D. Plywood - 1D G. Fibre - 1G H. Plastics removable head 1H2 Drums N. Metal, other than steel or aluminium removable head 1N2 A. Steel removable head 3A2 B. Aluminium removable head 3B2 Jerricans H. Plastics removable head 3H2 A. Steel - 4A B. Aluminium - 4B ordinary 4C1 C. Natural wood with sift-proof walls 4C2 D. Plywood - 4D F. Reconstituted wood - 4F G. Fibreboard - 4G H. Plastics expanded 4H1 solid 4H2 Boxes N. Metal, other than steel or aluminium - 4N The United Nations packaging symbol Plastic Drum with removable head For packing groups: I, II, III Maximum Gross mass in kilograms Carriage of Solids The State authorizing the allocation of the mark Name of Manufacturer Year of Manufacturing (last two digit) 22 Copyright © www.batteriestransport.org
RkJQdWJsaXNoZXIy MjQwNg==