General requirements
Used lithium-ion batteries are dangerous goods, and their packaging is set by the applicable packing instructions in the relevant transport code. Requirements generally include strong outer packaging, protection against short circuit, prevention of movement inside the package and protection against damage during normal handling.
Large EV batteries often cannot fit standard packaging and may be transported under special arrangements, such as robust crates or pallets that meet the code's requirements for large batteries. The exact route depends on the battery, its condition and the mode of transport.
- Terminals covered or otherwise protected against short circuit
- Non-conductive cushioning to prevent movement
- Outer packaging suited to the battery's mass and size
- Correct UN number, hazard labels and handling marks
- Packaging suited to the declared condition
Damaged and defective batteries
Batteries that are damaged, swollen, leaking or have suffered a thermal event need packaging designed for that risk. Typical solutions include metal containers with non-combustible, thermally insulating cushioning that can contain heat and absorb any leaked electrolyte. Some packaging systems are specifically tested for this purpose.
The declared condition drives the packaging choice, so accurate declaration is essential. A damaged battery shipped in standard packaging creates a serious risk for handlers and carriers.
Practical tips for holders
Use the packaging supplied by your collection partner rather than improvising. We provide approved containers, cushioning and labels free on registration, sized for the batteries declared on the manifest.
Before sealing, check state of charge, cover terminals, record the condition and photograph the battery. Keep packaging dry and store packed batteries away from heat sources until collection, which we schedule within five working days of manifest approval.