HOW TO SAFELY PACK AND SHIP BATTERIES PUBLISH DATE: MAY 22, 2012
HOW TO SAFELY PACK AND SHIP BATTERIES PUBLISH DATE: May 22, 2012 PUBLISH DATE: May 22, 2012 HOW TO SAFELY PACK AND SHIP BATTERIES Although they are very common today in portable electronics, tools and other applications, batteries can be a source of dangerous heat, sparks or fire if they are improperly packaged for shipping. For this reason, UPS customers must follow applicable safety regulations and appropriate precautions when preparing batteries for transportation. Battery shipments may be subject to both U.S. and international safety regulations, and because of the potential dangers associated with violations of those regulations, people who do not follow the regulations when packing their shipments could be subject to fines or other penalties. UPS has assembled these guidelines to help you safely pack and ship many kinds of batteries. In some cases, such as with alkaline or certain nonspillable lead-acid batteries, your responsibilities may be limited to simple steps such as: selecting strong outer packaging; carefully protecting battery terminals to prevent sparking or short circuit; and carefully preparing the interior package components to keep tools or other metal objects away from batteries. Other types of batteries, including lithium ion and lithium metal types, also may be fully regulated as hazardous materials (also known as dangerous goods) for transportation, so that in addition to those basic safety precautions they require use of specialized packaging, specific hazard labeling, and specific documents certifying compliance with the applicable regulations. As you review this brochure, please be aware of how your shipping practices comply with the guidance given here, and understand that some of your batteries may require you to review and comply with the U.S. Department of Transportation (DOT) Hazardous Materials Regulations (Title 49 of the Code of Federal Regulations) and/or the International Air Transport Association (IATA) Dangerous Goods Regulations (DGR). The IATA DGR is based on and produced in consultation with the International Civil Aviation Organization (ICAO) Technical Instructions. Additionally, other international regulatory requirements apply, such as the International Maritime Dangerous Goods (IMDG) Code, and the ADR Dangerous Goods Regulations for European Road Transport. © 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 2 PUBLISH DATE: May 22, 2012 HOW TO SAFELY PACK AND SHIP BATTERIES Protect Batteries and Terminals Types of Batteries When shipping almost any battery, you must protect all terminals against short circuits that can result in fires. Protect terminals by completely covering them with an insulating, non-conductive material (e.g., using electrical tape or enclosing each battery separately in a plastic bag), or packing each battery in fully enclosed inner packaging to ensure exposed terminals are protected. There are a variety of batteries available today and, while in transport, many are regulated as hazardous materials (also known as dangerous goods) that may only be shipped with UPS by shippers with contracts for hazardous materials/dangerous goods service. • 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 circuit battery terminals away from the batteries (e.g., using a separate inner box for the batteries). Note: To prevent fire, any device with installed batteries must not turn on while in transport. Protect switches that can be accidentally activated or remove the batteries and protect the terminals. Even very simple devices like flashlights or rechargeable drills can generate a dangerous amount of heat if accidentally activated. ID Number Proper Shipping Name and Description Hazard Class Packing Group UN2794 Batteries, Wet, Filled with Acid 8 II UN2795 Batteries, Wet, Filled with Alkali 8 II UN2800 Batteries, Wet, Non-Spillable 8 II UN3028 Batteries, Dry, Containing Potassium Hydroxide Solid 8 II UN3090 Lithium Metal Batteries 9 II UN3091 Lithium Metal Batteries Contained in Equipment or Lithium Metal Batteries Packed with Equipment 9 II UN3292 Batteries, Containing Sodium 4.3 II UN3480 Lithium Ion Batteries 9 II UN3481 Lithium Ion Batteries Contained in Equipment or Lithium Ion Batteries Packed with Equipment 9 II Some of the battery types shown above may be shipped under regulatory exceptions that do not require full compliance with the hazardous materials/dangerous goods regulations. In addition, there are some battery types (e.g., conventional dry cell or alkaline batteries in consumer sizes) that are not regulated at all, provided they are adequately protected against short circuit. © 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 3 PUBLISH DATE: May 22, 2012 HOW TO SAFELY PACK AND SHIP BATTERIES Wet Batteries (UN2794 and UN2795) — Not accepted in UPS small package services; permitted in UPS air freight and UPS ground freight These batteries are commonly used in cars, electric wheelchairs, forklifts, some continuous computer power sources and other applications. They contain highly corrosive acid or alkali and can cause fires from short circuit. All terminals must be protected against short circuit, and the batteries packaged and tested according to 49 CFR 173.159 for U.S. shipments, or IATA Section 5, Packing Instruction 870 (2011 edition). Note that air shipments must include an acid- or alkali-proof liner, or include supplementary packaging with sufficient strength and adequate seals to prevent leakage of electrolyte fluid in the event of spillage (see Figs. 1 and 2). Applicable shipping paper/Declarations for Dangerous Goods requirements must be met. Fig. 1 Sample Outer Packaging Wet Batteries Fig. 2 Sample Packaging Multiple Wet Batteries Terminal Protection Non-Conductive Divider Insulating Cap Inner Container Strong Outer Package Shipments of non-spillable acid or alkali batteries performed under the IATA Dangerous Goods Regulations must be fully declared and conform to the requirements of Packing Instruction 872 (2011 edition). Non-spillable acid or alkali batteries that comply with certain additional testing are not subject to any regulations, provided the terminals are protected against short circuit. These additional requirements, which are stated in 49 CFR 173.159a(d) and in IATA Section 4.4, Special Provision A67, require that the battery contain no free-flowing liquid, and the electrolyte must not flow from a cracked case at 55ºC (131ºF). The battery and package should be marked “NONSPILLABLE” or “NONSPILLABLE BATTERY.” Fig. 3 Sample Packaging Nonspillable Batteries Nonspillable Batteries (UN2800) These batteries may not be subject to the Hazardous Materials Regu lations if they meet the pressure differential and vibration testing in 49 CFR 173.159, as well as being plainly and durably marked either “NONSPILLABLE” or “NONSPILLABLE BATTERY” on the outer packaging (see Fig. 3). Conformance with 49 CFR 173.159a is mandatory and the batteries must be prepared for transport so as to prevent short circuit and unintentional activation of any devices or equipment in the package. © 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 4 PUBLISH DATE: May 22, 2012 HOW TO SAFELY PACK AND SHIP BATTERIES Dry Batteries, Containing Potassium Hydroxide Solid (UN3028) In the U.S., these batteries must be prepared according to Special Provision 237 in 49 CFR 172.102, which states that UN3028 materials “must be prepared and packaged in accordance with the requirements of 173.159(a), (b), and (c). For transportation by aircraft, the provisions of 173.159(b)(2) are applicable.” International air shipments of these types of batteries must conform to IATA 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 batteries are expected to change in early 2011. Readers of this information are urged to monitor the work of the U.S. Department of Transportation’s Pipeline and Hazardous Materials Safety Administration (PHMSA) for up to date information. Consult the following PHMSA web site for more information: http://hazmat.dot.gov. About Shipping Lithium Batteries by Air Service There are two kinds of lithium batteries, both of which contain very high levels of energy, usually in small cases: • Lithium ion (Li-ion) batteries, which are rechargeable. This type of battery includes those referred to as lithium polymer (Li-Po) batteries. 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 significant, meaning that such batteries can sometimes generate a great amount of heat if short circuited. In addition, the chemical contents of these batteries may catch fire if damaged, or improperly designed or assembled. For these reasons, there are safety regulations controlling the shipment of these types of batteries. Shippers must conform to the applicable sections of the U.S. Hazardous Materials Regulations and/or international regulations such as the International Air Transport Association’s Dangerous Goods Regulations. While both of these types of lithium batteries are classified as hazardous materials (also referred to as dangerous goods), there are exceptions for common small sizes of these batteries that simplify the rules for shipping these items. This document describes the rules for shipping these small 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 content”; — Batteries must not exceed 8 g of “equivalent lithium content.” You may calculate “equivalent lithium content” by multiplying the cell’s ampere-hours by 0.3. Since most small batteries are marked with milliampere-hours, you must first 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-hours by voltage. Since most small batteries are marked with milliamperehours, you must first divide milliampere-hours by 1,000 before multiplying the result by the battery’s voltage. Shipments of larger batteries are not given these exceptions and are thus fully regulated, and must be prepared as such. UPS requires a contract for shipment of these regulated hazardous materials/ dangerous goods. Restrictions apply to the types of hazardous materials/dangerous goods carried, and the service territory available for these shipments. Note: In recent years, there have been occasional recalls of defective lithium batteries. Never send recalled lithium batteries by air; doing so can be very dangerous and may result in fines or penalties against you, the sender. In addition, UPS does not transport recycled batteries by air. UPS air services that have the potential to travel by air include: UPS Next Day Air®, UPS 2nd Day Air®, UPS 3 Day Select®, International Express and International Expedited. UPS Ground service between Alaska, Hawaii or Puerto Rico and the continental U.S. is unavailable for either recalled or recycled batteries, as shipments in these lanes must travel by aircraft for at least one flight segment. Shipping Lithium Batteries — Without Electronic Equipment The rules for shipping small lithium batteries differ, depending on the type of battery involved and the type of battery you wish to send. The strictest rules apply to lithium metal batteries. Regardless of the battery type, one of the most important steps in preparing any battery for shipment is to protect against short circuits. © 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 5 PUBLISH DATE: May 22, 2012 HOW TO SAFELY PACK AND SHIP BATTERIES Lithium Batteries (UN3090, UN3091, UN3480, UN3481) (cont.) Short Circuit Protection As 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 the required protection. Other options include placing single batteries into a plastic bag (without other contents), putting non-conductive tape over battery terminals, or utilizing a design that recesses terminals enough that they cannot come into contact with conductive materials or other battery terminals. Never pack metal objects or other conductive items into the same package with batteries if there is an opportunity for those objects or items to come into contact with the batteries’ terminals. If it is necessary to send tools or other items with the batteries, separately contain properly protected batteries in a small box within a larger package that you use for the other items. Fig. 4 Sample Packaging Lithium Batteries Blister Pack Cushioning Divider • Small Lithium Metal Batteries — The chemistry of these batteries poses great fire risks when they are short-circuited, or if they are somehow damaged. For this reason, they must never be transported aboard passenger aircraft and must be marked to warn about the contents. Whether you plan to ship these batteries by air (in the UPS system or any flight to, from, within or through the U.S.) or ground (in the U.S.), the package must be marked with either of the two following statements (in letters at least 6 mm high for packages of up to 30 kg (66 lb) gross weight or 12 mm high for heavier packages): “PRIMARY LITHIUM BATTERIES—FORBIDDEN FOR TRANSPORT ABOARD PASSENGER AIRCRAFT” —or— “LITHIUM METAL BATTERIES—FORBIDDEN FOR TRANSPORT ABOARD PASSENGER AIRCRAFT” Packagings used for battery shipments need to be rugged enough to keep the contents from being crushed. For this reason, international rules always require a package that is capable of being dropped 1.2 meters (approximately 4 feet) without breaking open or damaging the batteries. This same requirement applies in the U.S. when packages contain more than 24 lithium cells or more than 12 lithium batteries. Strictly within the U.S., the gross package weight must not exceed 30 kg (66 lb). Any international shipment must be restricted to a gross package weight of 2.5 kg (5.5 lb). It is important to provide the necessary warnings on the outside of a package containing lithium batteries. International regulations require that any package of lithium metal batteries display a distinctive label (110 mm x 120 mm); the label may be reduced in size for smaller packages (74 mm x 105 mm): CAUTION! IF DAMAGED Lithium Metal Battery DO NOT LOAD OR TRANSPORT PACKAGE IF DAMAGED For more information, call ...................... © 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 6 PUBLISH DATE: May 22, 2012 HOW TO SAFELY PACK AND SHIP BATTERIES Lithium Batteries (UN3090, UN3091, UN3480, UN3481) (cont.) Short Circuit Protection (cont.) In addition to the statement discussed on page 6, U.S. domestic packages of lithium metal batteries may be marked with a warning that a package contains lithium batteries and that special procedures must be followed if the package is damaged. (This additional information is required if the package contains more than 24 cells or 12 batteries.) There are conditions under which a document should accompany these shipments as well, stating that the package contains lithium batteries, must be handled with care and that a flammability hazard exists if the package is damaged. The document also should state that special procedures are to be followed in the event the package is damaged, to include inspection and repacking if necessary. A telephone number for additional information is to be included. The document is required for any shipment under the international regulations, and is also required for U.S. domestic shipments containing more than 24 cells or more than 12 batteries. (This document, when required, may be affixed to a UPS package in a document pouch.) • Small Lithium Ion Batteries — Careful packaging also applies to shipments of rechargeable lithium batteries. These batteries do not require the marking that prohibits carriage aboard passenger aircraft. Packagings used for lithium ion battery shipments need to be rugged enough to keep the batteries from being crushed. For this reason, international rules always require a package that is capable of being dropped 1.2 meters (approximately 4 feet) without breaking open or damaging the batteries. This same requirement applies in the U.S. when packages contain more than 24 lithium cells or more than 12 lithium batteries. Strictly within the U.S., the gross package weight must not exceed 30 kg (66 lb). Any international shipment must be restricted to a gross package weight of 10 kg (22 lb). U.S. domestic packages may be marked simply with a warning that a package contains lithium batteries and that special procedures must be followed if the package is damaged. (This marking is required if the package contains more than 24 cells or 12 batteries.) There are conditions under which a document should accompany these shipments as well, stating that the package contains lithium batteries, must be handled with care and that a flammability hazard exists if the package is damaged. The document also should state that special procedures are to be followed in the event the package is damaged, to include inspection and repacking if necessary. A telephone number for additional information is to be included. The document is required for any shipment under the international regulations, and is also required for U.S. domestic shipments containing more than 24 cells or more than 12 batteries. (This document, when required, may be affixed to a UPS package in a document pouch.) Lithium Batteries Packed with or Contained in Equipment If you wish to ship a package containing a device that either has lithium batteries installed in it, or has its batteries packaged separately, there are similar safety regulations covering these types of shipments. By keeping the number of devices and batteries to a minimum, you will simplify your compliance requirements. U.S. rules become more complex when packages contain over 5 kg net weight of batteries or exceed a total of 24 cells or 12 batteries. (Guidance in this document is restricted to smaller shipments. For packages that exceed 5 kg net weight of batteries, or quantities over 24 cells or 12 batteries, you must consult the U.S. DOT Hazardous Materials Regulations, 49 CFR 172.102, Special Provision 188.) It is important to provide the necessary warnings on the outside of a package containing lithium batteries. International regulations require that any package of lithium ion batteries display a distinctive label (110 mm x 120 mm); the label may be reduced in size for smaller packages (74 mm x 105 mm): CAUTION! IF DAMAGED Lithium Ion Battery DO NOT LOAD OR TRANSPORT PACKAGE IF DAMAGED For more information, call ...................... © 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 7 PUBLISH DATE: May 22, 2012 HOW TO SAFELY PACK AND SHIP BATTERIES Lithium Batteries (UN3090, UN3091, UN3480, UN3481) (cont.) Lithium Metal Batteries Packed with Equipment or Contained in Equipment • Packed with Equipment — The batteries, fully protected against short circuit, must be placed into a rugged inner package that fully contains the batteries. The package should contain only the number of batteries required to operate the device. (Up to two spare batteries may be packed, provided all the international requirements are followed.) Communication requirements must also be followed. It is important to provide the necessary warnings on the outside of a package containing lithium batteries. International regulations require that any package of lithium metal batteries packed with equipment display a distinctive label (110 mm x 120 mm); the label may be reduced in size for smaller packages (74 mm x 105 mm): Lithium Ion Batteries Packed with Equipment or Contained in Equipment • Packed with Equipment — The batteries, fully protected against short circuit, must be placed into a rugged inner package that fully contains the batteries. The package should contain only the number of batteries required to operate the device. (Up to two spare batteries may be packed, provided all the international requirements are followed.) Communication requirements must also be followed. It is important to provide the necessary warnings on the outside of a package containing lithium batteries. International regulations require that any package of lithium ion batteries packed with equip ment display a distinctive label (110 mm x 120 mm); the label may be reduced in size for smaller packages (74 mm x 105 mm): CAUTION! CAUTION! IF DAMAGED IF DAMAGED Lithium Metal Battery DO NOT LOAD OR TRANSPORT PACKAGE IF DAMAGED For more information, call ...................... The package must be accompanied by a document stating that the package contains lithium batteries, must be handled with care and that a flammability hazard exists if the package is damaged. The document also should state that special procedures are to be followed in the event the package is damaged, to include inspection and repacking if necessary. A telephone number for additional information is to be included. (This document, when required, may be affixed to a UPS package in a document pouch.) • Contained in Equipment — The package is simplest to ship when there are no more than 4 cells or 2 batteries contained in the package. If the package contains more than this number, the communication requirements discussed above must also be followed. Lithium Ion Battery DO NOT LOAD OR TRANSPORT PACKAGE IF DAMAGED For more information, call ...................... The package must be accompanied by a document stating that the package contains lithium batteries, must be handled with care and that a flammability hazard exists if the package is damaged. The document also should state that special procedures are to be followed in the event the package is damaged, to include inspection and repacking if necessary. A telephone number for additional information is to be included. (This document, when required, may be affixed to a UPS package in a document pouch.) • Contained in Equipment — The package is simplest to ship when there are no more than 4 cells or 2 batteries contained in the package. If the package contains more than this number, the communication requirements discussed above must also be followed. © 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 8 PUBLISH DATE: May 22, 2012 HOW TO SAFELY PACK AND SHIP BATTERIES Dry Batteries, Sealed, n.o.s. These batteries are typically used for portable power applications, are hermetically sealed and generally use metals (other than lead) and/or carbon as electrodes. They must meet all the requirements set forth in Special Provision 130 in 49 CFR 172.102, which includes prevention of the dangerous evolution of heat from short circuit or damage. Under IATA, Special Provision A123 must be followed, which includes short circuit protection of exposed terminals and protection against accidental activation of the battery. Other Batteries Although common dry cells (e.g., AA, C, D batteries) may not be regulated as hazardous materials, all batteries can cause fires from short circuit if batteries and terminals are not protected. Each battery shipment must meet all the requirements set forth in Special Provision 130 in 49 CFR 172.102, which includes prevention of the dangerous evolution of heat from short circuit or damage. For air packages containing dry cell batteries with a voltage (electrical potential) that exceeds nine volts, the words “Not restricted” must be marked on the package to indicate compliance with the regulations. The equivalent requirement for IATA shipments is found in Section 4.4 of the IATA Dangerous Goods Regulations, as Special Provision A123 (see Fig. 5). Recalled or Recycled Batteries Never use air services to ship batteries recalled by the manufacturer for safety reasons, as such shipments are prohibited by regulation (i.e., IATA Dangerous Goods Regulations, Special Provision A154). Also, batteries accumulated for recycling are not to be sent via air services. These services include UPS Next Day Air, UPS 2nd Day Air, UPS 3 Day Select, International Express and International Expedited. UPS Ground service between Alaska, Hawaii or Puerto Rico and the continental U.S. is unavailable for either recalled or recycled batteries, as shipments in these lanes must travel by aircraft for at least one flight segment. Electronic Items for Repair Repair items, such as computers and cell phones, should be sent without batteries. Fig. 5 Sample Packaging Dry Cell Batteries Cushioning Blister Pack Divider While this document is designed to highlight safety practices for UPS customers who pack and ship batteries, it does not replace the applicable regulations. For more information, consult the U.S. DOT’s Hazardous Materials Regulations (49 CFR). You may also consult U.S. DOT’s online information at http://hazmat.dot.gov, or call the U.S. DOT’s Hazardous Materials Information Center at 1-800-467-4922. International air shipments may additionally be subject to the Dangerous Goods Regulations of the International Air Transport Association (IATA). For more information, see http://www.iata.org. © 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 9
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