Shipping lithium-ion batteries remains top of mind in 2026 - and for good reason. These batteries power everything from consumer electronics to electric vehicles and energy storage systems, but when something goes wrong in transportation, the consequences can be severe. Thermal runaway, fires, and transportation incidents continue to drive regulatory scrutiny.
That focus was reinforced in PHMSA’s November 2025 enforcement memo, which identified lithium-ion battery shipments as a priority for inspections and enforcement. For shippers, that means lithium batteries are not just regulated - they are actively scrutinized.
The guides published by PHMSA, Lion Technology, and carriers are excellent resources - and we strongly encourage shippers to use them. But they cannot anticipate every real-world scenario.
Knowing that lithium-ion battery shipping is complex and that questions often arise, we created a free 30-minute lithium battery compliance consultation dedicated specifically to battery shipments. This consultation gives you the opportunity to speak directly with one of our experts, walk through your specific situation, and get clear, practical answers before you ship.
One of the first questions emphasized across PHMSA and Lion Technology guidance is simple - but critical:
Are you shipping lithium-ion or lithium-metal batteries?
This article focuses on lithium-ion batteries, which are rechargeable and regulated under:
Misidentifying the battery type or UN number is one of the most common compliance issues seen during inspections.
Just as important is understanding why lithium-ion batteries are regulated. Damage, defects, improper packaging, or exposure to extreme conditions can trigger thermal runaway, a chain reaction that can cause overheating, fire, or explosion. This risk is the foundation of all lithium battery transport requirements.
PHMSA and Lion Technology both stress that energy density drives regulatory requirements.
For lithium-ion batteries, energy is measured in watt-hours (Wh). The watt-hour rating determines:
Batteries with higher watt-hour ratings face stricter requirements - particularly for air transport. This is one area where shippers often get stuck, especially when batteries are custom-built, embedded in equipment, or sourced from overseas suppliers.
Another key takeaway from the guides is that how the battery is packaged matters just as much as what it is.
Lithium-ion batteries may be shipped:
Standalone batteries are subject to the most stringent rules and are not permitted as cargo on passenger aircraft. Batteries shipped with or in equipment often have more flexibility - but only if packaged correctly.
Understanding these distinctions is essential when choosing transport modes and preparing shipments, especially for international or expedited air shipments.
Across all guidance documents, packaging requirements have one core goal: prevent damage, movement, and short circuits during transport.
Key principles include:
Carrier tools, like those provided by FedEx, reinforce that noncompliant packaging is one of the fastest ways to trigger shipment delays or refusals - even before regulatory inspections come into play.
PHMSA enforcement history shows that paperwork and markings are frequent failure points.
Depending on the shipment, requirements may include:
Even small errors - missing markings, outdated labels, or inconsistent descriptions - can result in delays, rejections, or enforcement actions.
One requirement that is easy to overlook: fully regulated lithium-ion battery shipments must list a 24/7 hazmat emergency phone number on the shipping papers (49 CFR 172.604), answered by someone who knows the shipment and can provide emergency response information.
Another consistent theme across PHMSA and Lion Technology guidance is that compliance depends on people, not just packaging.
Anyone involved in preparing, offering, handling, or transporting lithium-ion batteries must be properly trained. Beyond training, companies should have:
One of the most talked-about topics in lithium-ion battery shipping is State of Charge (SOC) - and for good reason. SOC refers to how much energy is stored in a battery at the time of transport. Higher stored energy increases the risk of thermal events if a battery is damaged or short-circuited in transit. Because of this, regulatory frameworks (especially IATA for air transport) limit the maximum SOC for lithium-ion batteries - often to 30% or lower for standalone cells and batteries. This requirement is designed to reduce fire risk on aircraft, but it also matters for ground and ocean shipments where damage can still occur.
Shippers should understand that:
Because SOC rules interact with other regulatory requirements and can differ internationally, it’s another great reason to talk to an expert - especially for unique configurations or cross-border shipments.
The guides published by PHMSA, Lion Technology, and carriers are excellent resources - and we strongly encourage shippers to use them. But they cannot anticipate every real-world scenario.
Knowing that lithium-ion battery shipping is complex and that questions often arise, we created a Hazmat Line free 30-minute consultation dedicated specifically to battery shipments. This consultation gives you the opportunity to speak directly with one of our experts, walk through your specific situation, and get clear, practical answers before you ship.
If you still have questions after reading this article - and reviewing the available battery guides - make sure to schedule your consultation. A short conversation can help you avoid costly mistakes, delays, or enforcement issues and ensure your shipments are safe, compliant, and hassle-free.