Shipping a healthy lithium battery is already a regulated activity. Shipping one that is swollen, recalled, or known to be defective is a different level of risk, and the rules reflect it. Batteries that are damaged can short-circuit, overheat and ignite, which is why regulators treat them separately from new, tested cells.
What counts as damaged, defective or recalled
In general terms, a battery is considered damaged or defective when it has been identified by the manufacturer as defective for safety reasons, or when it shows physical damage, leaking, swelling, or has overheated. Batteries subject to a safety recall also fall into a special category. Because the exact wording and requirements differ between the U.S. rules and the international air and ocean codes, always check the version currently in force for your mode of transport.
Why you cannot treat them like normal batteries
The usual shortcuts, such as the exceptions available for small quantities of undamaged cells, generally do not apply to damaged or defective batteries. They typically require packaging that can contain a thermal event, with non-combustible cushioning material, and they are often restricted or forbidden on certain modes, passenger aircraft in particular. Many shippers end up using ground or a specially approved arrangement.
Packaging approach
- Individually protect each battery against short-circuit by insulating terminals.
- Use a leakproof inner receptacle and non-combustible, absorbent cushioning.
- Place inside a UN-specification outer package authorized for the material.
- Mark and label as required, including identification as damaged or defective where applicable.
Packaging selection is where most mistakes happen. Our primer on UN-rated packaging explains how to match a package to the hazard.
Recycling and end-of-life flows
Used batteries heading to recyclers have their own provisions, and electronics retailers, e-waste handlers and fleet operators regularly move them. If you operate in the e-commerce space, the article on lithium batteries and e-commerce warehouse compliance covers receiving and returns. For Florida ocean exports, see lithium batteries by ocean from the Port of Miami.
Common mistakes
- Shipping a swollen battery as if it were a standard returned product.
- Assuming air is available when the mode is actually prohibited.
- Using generic cushioning that is combustible.
- Skipping the training requirement for the person who packs it.
Get it classified first
Because the consequences of a mistake are severe, ask for help before the first shipment. A hazmat consultation can establish the correct classification and a repeatable procedure, and hazmat training keeps your team current. When you are ready to move freight, send details through the quote form.
Frequently asked questions
Can damaged lithium batteries fly on a passenger aircraft?
Generally no. Damaged or defective lithium batteries are typically forbidden on passenger aircraft under international air rules. Check the current IATA DGR.
Do the small-battery exceptions apply to recalled batteries?
Usually not. Recalled, damaged or defective batteries are generally excluded from the exceptions that apply to normal batteries.
Who is allowed to package damaged batteries for shipment?
Only a trained person. Hazmat employees must complete function-specific training before preparing these shipments.
