EN 
ES 
FR 
PT 
AR 
Transporting batteries is far from trivial. Whether you’re shipping lithium packs for energy storage systems or smaller consumer cells, improper handling can lead to short circuits, fires, chemical leaks, or regulatory violations. This guide walks through essential best practices for transporting different battery types—lead-acid, nickel-based, and especially lithium—while staying compliant and safe.
Why Battery Transport Safety Matters
There have been real-world incidents where batteries caused fires or smoke in aircraft cargo holds, prompting stricter regulations worldwide. (Gotopower) Even though lithium batteries get the most attention, other chemistries like lead-acid, NiMH, NiCd, and alkaline can also pose hazards—particularly via short circuits or leaks. (Gotopower)
1. Lead-Acid Batteries
Lead-acid batteries are classified as Class 8 dangerous goods (UN 2794) when they are spillable. That’s because a short or acid leak can damage property or injure people. (Gotopower) Some sealed, non-spillable lead-acid batteries (grouped under UN 2800) are exempt from strict regulations—but the manufacturer must clearly state this in the MSDS. (Gotopower)
Best practices for transporting:
Always ship upright on pallets, with honeycomb cardboard or insulating layers between batteries.
Limit stacking (typically three layers max), wrap pallets with shrink film for stability.
Clearly mark with the “Corrosive” label, UN ID number, and “Wet, filled with acid” when applicable.
For damaged batteries, drain acid, neutralize it (e.g. using soda ash), and separate them from intact units in acid-resistant containers. (Gotopower)
2. Nickel-Based Batteries (NiMH / NiCd)
Nickel-based batteries have fewer constraints in transport. However:
You must still protect against electrical shorting: avoid mixing them with metallic objects like coins or keys.
Use insulating materials or individual plastic bags for each battery if there’s any risk of terminal contact.
Never transport small battery packs in metal boxes directly—they increase shorting risk. (Gotopower)
3. Lithium Batteries: The Stricter Rules
Lithium batteries—including lithium-ion and lithium-metal types—are treated most rigorously under transport regulations. All must pass UN 38.3 testing before they can be legally shipped. (Gotopower)
Key points:
Lithium batteries are classified as Class 9 dangerous goods. Exemptions exist for small consumer units (under 100 Wh or limited lithium content), but careful labeling and packaging are still required. (Gotopower)
For air transport, lithium batteries must be carried in cargo aircraft—never checked-in baggage. (Gotopower)
Airlines limit spare batteries per person (e.g. ≤ 100 Wh each, or total limits) and forbid them in checked luggage. (Gotopower)
All lithium battery shipments must follow Packaging Instructions (PI codes)—e.g. PI 965, 966, 967, 968, etc.—depending on whether the battery is loose, inside equipment, or lithium-metal. (Gotopower)
Batteries should be shipped at a partial state of charge (often ~30 % SOC) to reduce risk. (Gotopower)
The training of staff in dangerous goods handling is mandatory when shipping larger batteries. (Gotopower)
4. Practical Tips You Should Always Follow
Never pack batteries with metal objects (coins, keys) that could cause short circuits. (Gotopower)
Always insulate exposed terminals—use non-conductive pads, plastic bags, or wraps.
For lithium packs, declare correctly, include documentation (MSDS, UN 38.3 compliance), and use labels as required by IATA/ICAO.
Use certified carriers who understand “dangerous goods” regulations.
When in doubt, consult IATA’s Lithium Battery Guidance Document and relevant local regulatory policies. (Gotopower)
Transporting Lithium Batteries for ESS — What Our Team Recommends
For manufacturers and distributors of ESS systems (like those for South America), safe battery transport is a foundational requirement. From our experience, here are added recommendations:
Choose battery designs that pass UN 38.3 and be sure to keep certification documents ready for customs and carriers.
Maintain traceability of battery lots and never mix uncertified units with certified ones.
For large-scale shipments, consider sea or land freight for bulk volumes—these modes may have fewer restrictions than air transport (though local rules still apply).
Ensure packaging can withstand vibrations, temperature shifts, and handling during transit.
Transporting batteries is a field where errors can bring high risks. Whether for consumer packs or ESS modules, adherence to regulations, secure packaging, and the right documentation are non-negotiable.
Gotopower, as a manufacturer and distributor of lithium battery and ESS solutions, builds transport safety into our processes. All our batteries are verified to meet UN 38.3 standards, we provide comprehensive packaging guidelines, and partner with carriers experienced in dangerous goods logistics. When you work with Gotopower, you’re not just getting a battery—you’re getting reliability, compliance, and peace of mind all the way from our Shenzhen facility to your site.