Shipping Lithium Batteries in 2026: UN3480, UN3481, Air, Sea and Post

Classify first: chemistry, configuration and watt-hours

The UN number depends on the chemistry (rechargeable lithium ion or non-rechargeable lithium metal) and on how the batteries travel: by themselves, packed with the equipment they power (in the same box but not installed), or contained in (installed in) the equipment.

Size decides how strict the rules are. Lithium ion cells up to 20 Wh and batteries up to 100 Wh, and lithium metal cells with up to 1 g and batteries with up to 2 g of lithium, count as small. By air, small batteries packed with or in equipment can use Section II; by sea, small batteries in any configuration can use special provision 188. Larger ones are fully regulated in every mode, and by air so are all batteries shipped by themselves.

Watt-hours = nominal voltage (V) x capacity (Ah); divide mAh by 1,000 to get Ah. Lithium ion batteries must show their Wh rating on the outside case (IATA exempts only batteries made before 2009, or before 2012 for Section I).

Many e-bike and e-scooter batteries are rated above 100 Wh, so shipped alone they are fully regulated. Complete battery-powered vehicles have their own UN numbers (UN 3556 for lithium ion, replacing UN 3171 in the 2025-2026 rules); ask your forwarder how your product is classed.

• UN 3480 Lithium ion batteries: cells and batteries shipped by themselves, including power banks
• UN 3481 Lithium ion batteries packed with equipment, or contained in equipment
• UN 3090 Lithium metal batteries: cells and batteries shipped by themselves
• UN 3091 Lithium metal batteries packed with equipment, or contained in equipment

UN 38.3 testing and the test summary

Each cell and battery type must have passed the tests in section 38.3 of the UN Manual of Tests and Criteria (UN 38.3), including batteries installed in equipment.

Manufacturers and later distributors must make a test summary available. It names the manufacturer and test laboratory, gives the test report number and date, describes the cell or battery (type, mass, Wh rating, model), lists the tests with pass or fail results, cites the edition of the Manual used and names a responsible person. It has applied under the ICAO Technical Instructions and the IMDG Code since 1 January 2020 and under US rules since 1 January 2022; button cells installed in equipment are exempt.

PHMSA says a general statement on a safety data sheet (SDS) does not meet the requirement. The summary need not travel with each shipment; it can be made available on a website, for example by URL or QR code.

By air: IATA packing instructions 965 to 970

Air shipments follow the ICAO Technical Instructions (2025-2026 edition), which airlines apply through the IATA Dangerous Goods Regulations (67th edition, 2026). Lithium ion: PI 965 (UN 3480 alone), PI 966 (packed with equipment), PI 967 (contained in equipment). Lithium metal: PI 968 (UN 3090 alone), PI 969 (packed with), PI 970 (contained in).

Section II covers small cells and batteries packed with or in equipment, within set quantities. Section I covers larger ones and those over the Section II limits; for batteries shipped alone it is split into Section IA (larger) and Section IB (small cells and batteries). Batteries shipped alone have no Section II, so they are always fully regulated: Shipper's Declaration for Dangerous Goods, Class 9 label and trained staff. Section II needs no declaration, and staff need adequate instruction rather than full dangerous goods training.

UN 3480 and UN 3090 are forbidden as cargo on passenger aircraft and go on cargo aircraft only; UN 3480 must be at no more than 30% state of charge. From 1 January 2026, lithium ion batteries packed with equipment (PI 966) must also be at 30% or less; in Section II this applies to cells and batteries over 2.7 Wh. For batteries contained in equipment (PI 967), 30% (or an indicated capacity of 25%) is recommended, not required. Batteries with or in equipment may fly on passenger aircraft up to 5 kg of batteries per package.

Batteries that are damaged, or that the manufacturer has identified as defective for safety reasons, are forbidden by air, including those in devices recalled for safety reasons.

• Lithium battery mark (red hatched border, UN number, at least 100 x 100 mm or 100 x 70 mm on small packages): Section II and Section IB packages, not Section IA
• Class 9 lithium battery hazard label: fully regulated packages (Sections I, IA and IB)
• Cargo Aircraft Only label: all PI 965 packages (Sections IA and IB) and other cargo-aircraft-only shipments
• No mark needed for packages with only button cells installed in equipment, or for consignments of up to two packages each holding no more than four cells or two batteries installed in equipment
• Section II limits: up to 5 kg of batteries per package; packed with equipment, no more than needed to power it plus two spare sets
• Section II paperwork: the air waybill states, for example, "Lithium ion batteries in compliance with Section II of PI 967"

Express couriers and airlines add their own rules

Airlines and express networks publish operator variations in the IATA regulations and their own battery guides, which can be stricter than the rules above and differ by service and route. Check the carrier's own dangerous goods page before you quote a price or delivery date. Examples from their 2025-2026 documents:

• DHL Express (guide effective 1 January 2026): many lithium battery shipments need an approved account on its time definite international service; lithium metal batteries shipped alone (PI 968 Section IB) are barred to, from and within Asia Pacific on that service; damaged, defective and waste batteries are refused.
• FedEx (Europe guide): Section I, IA and IB battery shipments are accepted at dangerous goods locations only; Section II at most locations.
• UPS: shippers need a signed agreement to ship dangerous goods; UN 3480 and UN 3090 in Section IA are barred to, from and within Europe on Worldwide Express Freight; Section II packages to or from places outside the 48 contiguous US states and Puerto Rico must also be marked with the packing instruction and section.
• Whatever the carrier, fully regulated shipments need a Shipper's Declaration signed by trained staff.

By sea: IMDG Code and special provision 188

Sea shipments follow the IMDG Code. Amendment 42-24 has been mandatory since 1 January 2026 (optional from 1 January 2025); it clarifies what "make available" means for the test summary and moves battery-powered vehicles from UN 3171 to UN 3556, 3557 and 3558.

Special provision 188 exempts small cells and batteries (the same 20 Wh / 100 Wh and 1 g / 2 g limits) from the rest of the Code if they are UN 38.3 tested, protected against short circuit and in strong packaging. Packages carry the lithium battery mark (with the same exceptions as by air), must pass a 1.2 m drop test unless the batteries are installed in equipment, and may weigh up to 30 kg gross unless the batteries are installed in or packed with equipment. No dangerous goods declaration is needed, but CINS guidance says the shipping line should still be told the container holds lithium ion cells.

Larger batteries, and any that do not meet special provision 188, are fully regulated: packed under packing instruction P903, with Class 9 labels, a dangerous goods declaration, a container packing certificate and placards, and booked as dangerous goods through your forwarder.

Damaged or defective batteries are not banned by sea as they are by air, but special provision 376 allows them only in special packaging (P908, or P911 if they could react dangerously). The 30% state-of-charge limits above are air rules.

By post: only batteries installed in equipment

Under Universal Postal Union rules in force since 1 January 2013, posts may accept international items containing equipment with up to four lithium cells or two lithium batteries installed in it, if their national civil aviation authority approves. Batteries on their own are not accepted, and each post decides whether to offer the service.

USPS, for example, takes lithium ion and lithium metal batteries internationally only when installed in the equipment they operate (UN 3481, UN 3091): up to four cells or two batteries, cells up to 20 Wh or 1 g and batteries up to 100 Wh or 2 g, at most two mailpieces per shipment, and no lithium battery mark. Batteries alone or packed with (not in) equipment, and damaged, defective or recalled batteries, cannot be mailed internationally.

Whatever the mode, this note is general guidance. Dangerous goods must be classified, packed, marked and declared by trained staff or a qualified forwarder under the current ICAO/IATA, IMDG or national rules and the carrier's own conditions.