Lithium Battery Shipping from Global: UN3480, UN3481 Compliance Guide

China is the world's largest producer of lithium batteries, manufacturing over 75% of global supply. From electric vehicle battery packs to consumer electronics, power tools, and energy storage systems, lithium batteries are among the most exported products from Global — and also one of the most heavily regulated. Because lithium batteries carry a genuine fire and explosion risk, shipping them requires strict compliance with international dangerous goods regulations.

This guide provides a comprehensive overview of lithium battery shipping from Global, covering UN number classification (UN3480, UN3481, UN3090, UN3091), packaging requirements, labeling standards, documentation, airline restrictions, and maritime transport requirements for 2026.

Understanding Lithium Battery UN Numbers

The first step in compliant battery shipping is identifying the correct UN number. Lithium batteries are classified into four UN numbers based on battery type (lithium-ion vs. lithium-metal) and whether the battery is packed alone or contained in equipment:

UN Number	Battery Type	Description	Class
UN3480	Lithium-ion	Lithium-ion batteries packed alone (standalone)	Class 9 (MI)
UN3481	Lithium-ion	Lithium-ion batteries packed with or contained in equipment	Class 9 (MI)
UN3090	Lithium-metal	Lithium-metal batteries packed alone (standalone)	Class 9 (MI)
UN3091	Lithium-metal	Lithium-metal batteries packed with or contained in equipment	Class 9 (MI)

Lithium-Ion vs. Lithium-Metal Batteries

Lithium-ion batteries (UN3480/UN3481) are rechargeable and used in phones, laptops, EVs, power tools, and energy storage. They are the most commonly shipped battery type from Global. The key metric is Watt-hour (Wh) rating.

Lithium-metal batteries (UN3090/UN3091) are typically non-rechargeable (primary cells) and used in watches, medical devices, and military equipment. The key metric is lithium content in grams. Lithium-metal batteries are subject to stricter transport restrictions because they carry a higher fire risk.

Watt-Hour Rating Thresholds

For lithium-ion batteries, the Watt-hour (Wh) rating determines the applicable shipping requirements:

• ≤ 20 Wh (cell) or ≤ 100 Wh (battery): Eligible for Section II provisions (reduced requirements) in air freight.
• > 100 Wh: Full dangerous goods regulations apply. Requires DGD, UN packaging, and all labeling.
• > 100 Wh but ≤ 300 Wh (large batteries): Subject to additional quantity limits and packaging requirements.

Packaging Requirements for Lithium Batteries

Proper packaging is the most critical compliance element for lithium battery shipping. Packaging must prevent short circuits, physical damage, and thermal runaway propagation.

General Packaging Principles

• Prevent short circuits: Each battery must be individually packed in inner packaging that completely encloses the battery. Conductive materials must not contact battery terminals.
• Prevent movement: Batteries must be secured to prevent movement within the outer packaging. Use cushioning material to fill voids.
• Prevent accidental activation: For batteries packed with equipment, the equipment must be switched off or the battery must be isolated from the equipment circuit.
• Strong outer packaging: Use rigid, durable outer packaging that meets UN specification standards where required.

UN3480 — Standalone Lithium-Ion Batteries

Standalone lithium-ion batteries require the strictest packaging. For shipments exceeding 100 Wh, UN-specification packaging is mandatory. The packaging must be tested and marked with a UN specification code (e.g., 4G/Y20/S/26/CN/...). Inner packaging must use non-conductive materials, and each battery or cell must be separated to prevent contact. Maximum net weight per package is typically 35 kg for cargo aircraft.

UN3481 — Batteries Packed With or In Equipment

When lithium-ion batteries are packed with equipment (in the same package but not installed), they must be in inner packaging that prevents short circuits and movement. The equipment itself must be secured. When batteries are contained in equipment (installed), the equipment must prevent accidental activation and damage to the battery. UN-specification packaging is not always required for batteries ≤ 100 Wh contained in equipment, but strong outer packaging is still mandatory.

UN3090/UN3091 — Lithium-Metal Batteries

Lithium-metal batteries follow the same packaging principles as lithium-ion, but with additional restrictions. Standalone lithium-metal batteries (UN3090) face even stricter air transport limits — many airlines refuse them entirely. Lithium content per cell must not exceed 1 gram, and per battery must not exceed 2 grams for certain reduced-regulation provisions.

Labeling and Marking Requirements

Incorrect or missing labels are the most common cause of customs holds and carrier rejections. Every lithium battery shipment must display the following:

1. Class 9 Hazard Label

All lithium battery shipments classified as fully regulated dangerous goods (batteries > 100 Wh) must display the Class 9 Miscellaneous Dangerous Goods hazard label. This diamond-shaped label features vertical black stripes on a white background with a flame symbol at the top. The minimum dimensions are 100mm x 100mm (smaller versions are permitted for small packages).

2. Battery Handling Mark (Lithium Battery Mark)

The lithium battery mark is required for most lithium battery shipments, including those eligible for reduced regulations. This mark features a hatched border with a battery symbol and an image of batteries undergoing damage. As of January 1, 2026, the mark must display the UN number(s) (e.g., "UN3480") and a telephone number for additional information. Minimum dimensions are 100mm x 100mm (or 100mm x 70mm for smaller packages).

3. Cargo Aircraft Only Label

For UN3480 and UN3090 shipments (standalone batteries) transported by air, a "Cargo Aircraft Only" label is mandatory. This label indicates the package must not be loaded on passenger aircraft.

4. Package Orientation Labels

If the package contains liquid electrolyte or requires specific orientation, "This Way Up" arrows must be displayed on at least two opposite sides.

Documentation Requirements

Proper documentation is essential for compliance and smooth customs clearance. The key documents for lithium battery shipping include:

1. Shipper's Declaration for Dangerous Goods (DGD)

For fully regulated shipments (batteries > 100 Wh shipped by air, or any standalone batteries), a DGD is required. This IATA-standard form declares the proper classification, packaging, and quantity of the dangerous goods. The DGD must be signed by the shipper and presented to the carrier. For sea freight under IMDG Code, a container/vehicle packing certificate and dangerous goods declaration are required.

2. UN38.3 Test Summary Report

The UN38.3 test (UN Manual of Tests and Criteria, Part III, subsection 38.3) is a mandatory safety test for all lithium batteries shipped internationally. Since January 1, 2020, manufacturers must provide a Test Summary Report proving the battery type has passed all eight UN38.3 test requirements. This document must be available before shipping and is frequently requested by carriers and customs authorities in China.

The eight UN38.3 tests include: altitude simulation, thermal test, vibration, shock, external short circuit, impact/crush, overcharge, and forced discharge. Each battery type must pass all tests before it can be legally shipped.

3. Material Safety Data Sheet (MSDS)

An MSDS (also called SDS — Safety Data Sheet) provides detailed information about the battery's chemical composition, hazards, handling procedures, and emergency response measures. While not always a formal regulatory requirement, most carriers and forwarders require an MSDS before accepting lithium battery shipments.

4. Air Waybill / Bill of Lading

The transport document (AWB for air freight, B/L for sea freight) must include the proper shipping name, UN number, class, packing group (if applicable), number of packages, and net or gross weight. For air freight, the "Shipper's Declaration for Dangerous Goods" checkbox must be marked.

5. Certificate of Origin and Export Documents

Standard Chinese export documents including commercial invoice, packing list, and customs declaration are required. For battery exports, China Customs may also request the UN38.3 test report and dangerous goods packing certificate.

Air Freight Requirements and Airline Restrictions

Air freight is the fastest option for lithium battery shipping but also the most restrictive. The IATA Dangerous Goods Regulations (DGR) govern air transport of lithium batteries, and individual airlines may impose additional restrictions.

IATA DGR Provisions

Under IATA DGR, lithium batteries are classified under Packing Instructions (PI) 965 (UN3480), 966 (UN3481 packed with equipment), 967 (UN3481 contained in equipment), 968 (UN3090), 969 (UN3091 packed with equipment), and 970 (UN3091 contained in equipment). Each PI has specific quantity limits and packaging requirements.

PI	UN Number	Section	Passenger Aircraft	Cargo Aircraft
965	UN3480	IA (>100 Wh)	Forbidden	Max 35 kg/pkg
965	UN3480	IB (≤100 Wh)	Forbidden	Max 10 kg/pkg
965	UN3480	II (≤20 Wh cell)	Forbidden (CAO only)	Max 2.5 kg/pkg
966	UN3481	II (with equipment)	Max 5 kg/pkg	Max 5 kg/pkg
967	UN3481	II (in equipment)	Max 5 kg/pkg	Max 5 kg/pkg

Airline-Specific Restrictions

Many major airlines have implemented their own policies that go beyond IATA DGR requirements:

• Cathay Pacific: Does not accept UN3480 on any aircraft, passenger or cargo.
• Qatar Airways: Accepts UN3480 on cargo aircraft only with pre-approval and additional documentation.
• Emirates SkyCargo: Accepts lithium batteries but requires UN38.3 test summary and MSDS for all shipments.
• Chinese carriers (CA, MU, CZ, HU): Accept UN3480/UN3481 on cargo aircraft with proper documentation. Some require pre-approval from the airline's dangerous goods department.
• FedEx and UPS: Accept lithium batteries under IATA DGR with additional company-specific labeling and documentation requirements.

Always confirm carrier acceptance before producing or packaging the goods. Carrier policies change frequently, and what was accepted last month may be restricted today.

Sea Freight Requirements for Lithium Batteries

Sea freight is the preferred mode for large-volume lithium battery shipments from Global. The IMDG Code (International Maritime Dangerous Goods Code) governs sea transport of dangerous goods, and lithium batteries are classified as Class 9.

IMDG Code Provisions

Under the IMDG Code, lithium batteries are classified under UN3480, UN3481, UN3090, or UN3091 with Special Provisions 188, 230, 376, and 377. Key requirements include:

• UN-specification packaging for standalone batteries exceeding the reduced-regulation thresholds.
• Class 9 hazard label and lithium battery mark on each package.
• Dangerous goods declaration and container packing certificate.
• Stowage away from heat sources and in well-ventilated areas.
• "On deck only" stowage may be required for certain battery types.

Container Requirements

Lithium batteries are typically shipped in standard dry containers. However, some shipping lines require dangerous goods containers or specific stowage positions. For large EV battery packs, flat rack or open top containers may be needed. Refer to our special container guide for oversized battery shipments.

Marine Insurance

Lithium battery shipments require specialized marine cargo insurance. Standard cargo insurance policies often exclude or limit coverage for dangerous goods. Ensure your policy explicitly covers lithium batteries and includes thermal runaway and fire damage coverage. Premiums typically run 0.3-0.8% of cargo value, depending on battery type, quantity, and route.

Common Compliance Pitfalls

Based on our experience handling lithium battery exports from Global, the most common compliance issues include:

1. Missing or Incorrect UN38.3 Test Summary

Many shippers do not realize that the UN38.3 Test Summary is mandatory. Without it, carriers will reject the shipment, and Chinese customs may seize the cargo. Always obtain the test summary from the battery manufacturer before shipping.

2. Incorrect Watt-Hour Rating

The Wh rating determines the applicable regulations. If the declared Wh rating is incorrect, the shipment may be under-classified, leading to rejection, fines, or safety incidents. Verify the Wh rating from the manufacturer's specifications and ensure it matches the labeling.

3. Inadequate Inner Packaging

Batteries touching each other or conductive materials is a leading cause of rejection. Each battery must be individually enclosed in non-conductive inner packaging. Tape over terminals as an additional safeguard.

4. Outdated Lithium Battery Mark

The lithium battery mark design has been updated. The current mark (with UN number and phone number) must be used. Old marks without the UN number are no longer compliant as of 2026.

5. Attempting to Ship UN3480 on Passenger Aircraft

This is strictly prohibited. If discovered, the shipment will be offloaded, and the shipper may face legal consequences. Always route standalone lithium batteries via cargo aircraft or sea freight.

Best Practices for Lithium Battery Export from Global

• Work with a certified DG forwarder: Use a forwarder licensed to handle dangerous goods, like SHAQ Logistics, with experience in battery shipments.
• Obtain all documentation early: Request UN38.3 test summary, MSDS, and DG packing certificate from the manufacturer before production is complete.
• Pre-book carrier space: Lithium battery cargo space is limited, especially on cargo aircraft. Book 1-2 weeks in advance.
• Use experienced packers: Have batteries packed at a certified DG packing facility, not at the factory, to ensure compliance.
• Conduct pre-shipment inspections: Inspect packaging, labeling, and documentation before the cargo leaves the warehouse.
• Maintain records: Keep copies of all DG documentation for at least two years as required by regulations.

Conclusion

Shipping lithium batteries from Global is a complex but manageable process when you understand the regulations and follow compliance procedures. The key is proper classification (UN3480, UN3481, UN3090, UN3091), robust packaging that prevents short circuits, accurate labeling, complete documentation including the UN38.3 test summary, and carrier pre-approval.

As global demand for lithium batteries continues to grow — driven by EVs, renewable energy storage, and consumer electronics — compliance requirements are only becoming stricter. Partnering with an experienced dangerous goods freight forwarder ensures your shipments move safely, legally, and on time.

SHAQ Logistics is a licensed NVOCC and dangerous goods forwarder with extensive experience shipping lithium batteries from Global to global destinations. Contact us for a free consultation and DG shipping quote within 24 hours.