The growing demand for lithium batteries means that if you need to expand your lithium business into France, you need to pay attention to the introduction of standards and regulations that effectively manage the transportation of lithium batteries.
Today, we live in a world where energy drives almost all human activities: from agriculture to heavy industry, to services and “personal technology”, every industry relies on energy. The industrial electrification sector also follows this trend: driven by the increasing urgency of international sustainable development policies and the obvious advantages of energy transition, the sector is currently booming.
In recent years, the term electrification has most often been associated with lithium batteries. Initially, these batteries were mainly used in computers and small power tools, but they have gradually become essential for the electrification of hybrid and electric vehicles. Today, industrial machinery manufacturers and electric vehicle producers are increasingly focusing on this technology to achieve the electrification transformation of their fleets and installations.
The sharp increase in demand has led to the need to bring these products to the international market. This has resulted in a significant increase in transport volume. Therefore, it is necessary to introduce standards and regulations to better manage the transportation of lithium batteries.
Transporting Dangerous Goods: The Case of Lithium Batteries
The safety of lithium batteries is a key concern for users throughout the supply chain, including transportation.
Today, there are various lithium-based chemistries on the market, each with its specific characteristics that make it more or less suitable for a given application. However, chemistry is not the only determinant of lithium battery performance. Another key factor is the Battery Management System (BMS).
A smart BMS optimizes the properties of the selected chemistry. By managing and controlling all components that interact with the battery, it ensures long-term reliable and consistent performance.
C-rate, thermal stability, and specific energy are some characteristics related to the thermal, chemical, electrical, and kinetic risks associated with batteries. Therefore, lithium batteries, like chemicals or flammables, are classified as dangerous goods. Like any other hazardous material, they can be transported by all available means: road, sea, rail, or air.
However, being classified as dangerous goods, their transport is subject to specific regulations to ensure that they are properly managed and protected during transport and storage. This is to prevent dangerous situations, such as fires. For this reason, lithium batteries are classified as dangerous goods, and their handling, both domestically and internationally, is governed by relevant European regulations.
Lithium Battery Transportation Safety Rules and Requirements
When transporting lithium batteries, specific handling procedures are required, including special packaging for safe transport. To ensure the safe transportation of lithium batteries, adherence to the relevant rules and regulations outlined in the UN Manual of Tests and Criteria is essential.
Lithium batteries, once properly certified and specially packaged, can be transported by road, sea, rail, or air. However, medium-sized and large batteries are classified as dangerous goods and are not accepted by most airlines, especially for cargo flights.
All goods classified as “Dangerous Goods” must comply with the specific requirements outlined in the UN Manual of Tests and Criteria. This document outlines regulations for the safe handling and transport of hazardous materials, with Section 38.3 specifically details the specifications for lithium-ion batteries.
UN 38.3 Certification for Lithium Batteries
UN 38.3 certification is mandatory for the safe handling of batteries during domestic and international transportation, except for prototypes or small production runs. This certification is crucial for avoiding penalties, customs holds, and ensuring the safety of the shipment.
The UN 38.3 standard certifies that batteries meet the requirements for all modes of transportation and have passed a series of rigorous tests as prescribed by the regulations.
UN 38.3 Testing Process
To obtain UN 38.3 certification, lithium batteries must undergo a series of eight rigorous tests conducted by an independent, accredited testing center to ensure their safety during transportation.
The tests required for a UN 38.3 report are as follows:
- T1. Altitude Simulation Test
This test simulates the environment of an unpressurized aircraft cargo compartment at an altitude of 15,000 meters. The battery is exposed to a low pressure of 11.6 kPa for at least 6 hours. After the test, certain criteria regarding mass loss, leakage, rupture, explosion, or fire must be met. The open circuit voltage of the battery after the test should be no less than 90% of its voltage before the test. - T2. Thermal Test
The battery is kept at +72°C for 6 hours and then at -40°C for 6 hours, for a total of 10 cycles. This test can be performed in a temperature chamber or a thermal shock test chamber. - T3. Vibration Test
This test simulates the vibrations typically encountered during transportation. - T4. Shock Test
This test simulates the shock that batteries may experience during transportation by subjecting them to strong acceleration. - T5. External Short Circuit Test
This test simulates an external short circuit, where the battery terminals are shorted to understand how they react in the event of an accident. - T6. Impact Test
This test is only applicable to primary (non-rechargeable) cells and secondary (rechargeable) cells. The battery is subjected to an impact from a 9.1 kg weight, simulating a drop of the packaging before transportation. - T7. Overcharge Test
This test simulates an overcharge condition for rechargeable batteries, where they are continuously charged at the manufacturer’s recommended charging current for 24 hours.
T8. Forced-Discharge Test
This test simulates a forced discharge of the battery over its entire capacity.
Battery Test Summary: Compliance Documentation
Once the battery has been verified as compliant with all the standards outlined in Section 38.3 of the Manual of Tests and Criteria, the department responsible for export logistics must ensure that the documentation accompanying the shipment and related to labeling is accurate and complete.
In fact, since January 1, 2020, the latest revision of the Manual of Tests and Criteria requires that each battery be suitable for transport must be accompanied by a document called a “Battery Test Summary Report.” This document summarizes all the information and identifying characteristics of the battery, as well as the various tests carried out, to facilitate identification and verify its safety during transport.
How are lithium batteries classified? What regulations govern their transport?
The transport of dangerous goods, and in particular lithium batteries, is governed by specific regulations that vary depending on the mode of transport chosen. These regulations are both European and international, and carriers must comply with them:
- RID: European regulations governing rail transport (RID)
- ADR: European agreement governing road transport (ADR)
- ADN: International agreement governing inland waterway transport (ADN)
- IMDG: International reference code for maritime transport (IMDG)
- DGR: Global standard for air transport (DGR)
Each regulation outlines the safety requirements for transporting these dangerous goods and specifies the obligations and responsibilities that all parties involved must fulfill. These regulations also provide information on cargo classification criteria, the most suitable packaging, transport conditions, labeling of packages and transport units, the drafting of transport documents, and the appropriate type of vehicle.
Classification of Batteries for Transport
Like other items classified as “dangerous goods,” lithium batteries are also assigned a specific hazard class. Lithium-ion batteries fall under Class 9: as Miscellaneous dangerous substances and articles.
This means that all such goods must display the specific label for this class.
To ensure complete safety during transport, regulations divide lithium batteries into two categories:
- Rechargeable batteries (typically lithium-ion batteries)
- Non-rechargeable or primary batteries
Another distinction relates to their packaging:
- Individual batteries
- Batteries contained in equipment (e.g., cars, vehicles, or general equipment)
- Batteries inserted inside the equipment itself
UN Code to Identify the Type of Goods
After defining the nature of the material to be transported and its transport characteristics, the corresponding UN code (consisting of four digits preceded by the abbreviation “UN”) is assigned to classify the type of goods being transported.
International Classification of Lithium-Ion Batteries
The dangerous goods classification system was developed by the United Nations Economic Commission for Europe’s international committee to clearly identify specific types of dangerous goods globally. For rechargeable lithium-ion batteries, the designated codes are UN3480 and UN3481.
- Class 9 – UN3480 – Lithium-ion batteries – Not packed with or contained in equipment.
This UN code is used to identify lithium-ion batteries that are shipped separately from the equipment they are intended to be used in by the end customer.
- Class 9 – UN3481 – Lithium-ion batteries contained in equipment – Batteries contained or integrated/installed in equipment.
Batteries already installed in equipment and shipped with that equipment to its destination fall under the UN3481 code. This classification applies to lithium-ion batteries that are packaged with equipment or devices but are not directly installed or connected, as well as lithium-ion batteries that are installed and connected to the equipment for use.
Additional Requirements for Lithium Batteries: Information for Carriers
Once the correct classification (UN3480 or UN3481) for a specific lithium battery has been accurately identified, the following additional information must be provided: weight, dimensions, capacity, and battery condition.
The “battery condition” section is critical to ensure appropriate packaging and to avoid issues with the carrier. Battery conditions can be classified as follows:
- New batteries
- Defective or non-functioning batteries (casing undamaged)
- Batteries for disposal or recycling
- Batteries severely damaged (due to accidents or testing)
- Prototype batteries or small production runs (less than 100 pieces)
Transport authorities may require specific packaging for declared damaged batteries to ensure the safety of handling personnel.
Value Chain from Battery Design to Transportation: Keheng’s Experience
All Keheng lithium batteries customized for industrial equipment and electric vehicles comply with the UN 38.3 certification requirements outlined in the Manual of Tests and Criteria. Keheng’s lithium batteries strictly adhere to all safety measures to ensure the highest quality standards throughout the value chain, from design and transportation to procurement.
Beyond certification, the safety precautions taken by manufacturers play a crucial role in ensuring the complete safety of lithium batteries, especially in electrified equipment and vehicles. If you are interested in learning more about the safety and benefits of lithium batteries, you can check out our comparison of a Lithium Iron Phosphate Battery vs. Lithium-Ion Battery. (Please note that the linked page is in English)
At Keheng, in addition to using the safest and most stable LFP (Lithium Iron Phosphate) chemical material on the market, we also choose to assemble only 4 cells in parallel in each battery. This is because fewer cells result in a higher safety level in the event of a short circuit. We have also developed an intelligent battery management system to fully leverage the selected chemical material’s properties, ensuring the battery’s lasting safety and reliability.
