Safety Tips for Lithium-ion Battery Transport

Transporting lithium-ion batteries requires careful consideration and adherence to safety guidelines due to the potential risks associated with these energy-dense devices. From compliance with regulations to packaging, monitoring and temperature control, we take you through the tips for safer lithium-ion battery transport.

How do you Transport Lithium Batteries in Australia?

As lithium-ion batteries are regarded as Class 9 dangerous goods, they fall within the Australian Dangerous Goods Code (ADG Code) for requirements relating to road transport.

The ADG Code includes regulations for the transport of lithium batteries, including meeting testing requirements, being manufactured to conformity and batteries being equipped with an effective means of pre-venting external short circuits.

Rechargeable lithium-ion batteries are categorised with a UN Number, as per the below table:

Therefore, they must be properly packaged and labeled if they are travelling with a freight management company.

To mitigate risk, various safety measures and regulations have been established for the commercial transportation of lithium-ion batteries. If you are shipping your batteries with a carrier, make sure you check their requirements for shipment prior to packaging your Class 9 dangerous goods.

However, there is not a lot of information relevant to businesses who are simply moving or transporting their lithium-ion batteries around their workplace, to other sites or to waste disposal services.

Safety Data Sheets for Lithium Battery Transport

Section 14 of your safety data sheets will provide you with the transport information that relates to your lithium-ion batteries, including it’s UN Number.

Your safety data sheet will also detail a range of information including temperature limits, incompatibilities, hazards and PPE for the handling of the Li-ion batteries. All of this must be considered when working with a lithium-ion battery.

However, there are some serious considerations to make when moving batteries to ensure safety for your staff and others on the road.

Example of Section 14 Transport Information for a lithium-ion rechargeable battery.

Let’s have a look at some of the hazards associated with the road transport of lithium-ion batteries — and what you can do about it.

Dangers of Transporting Lithium-ion Batteries

What are some of the hazards that can occur when you’re transporting your lithium-ion batteries in your utility vehicle or truck?

Transporting lithium-ion batteries — while a common practice for many industries including mining, energy, construction, medical and industrial applications — does pose certain risks and dangers.

Here are some of the potential hazards associated with transporting lithium-ion batteries:

• Short Circuits: Poorly designed packaging or storage conditions may increase the risk of short circuits during transportation, which can result in overheating and fire.
• Fire and Thermal Runaway: Lithium-ion batteries are sensitive to physical damage, high temperatures, and overcharging. If a battery is damaged or experiences a thermal runaway (uncontrolled increase in temperature), it can lead to fire or explosion. This risk is higher if the batteries are not properly packaged or if they are damaged during transport. If you’d like to learn more about thermal runaway, why not take a look at our recent blog, Lithium-ion Batteries and Thermal Runaway.
• Chemical Exposure: In the event of a fire or damage to the battery, there is a risk of exposure to hazardous chemicals within the battery. Not only can the flammable electrolyte ignite, but these chemicals also have corrosive and toxic properties that are harmful to humans and living organisms.
• Packing and Labeling: Incorrect packaging and labeling can lead to mishandling or improper storage of lithium-ion batteries. It's crucial to follow specific regulations and guidelines for packing and labeling to ensure safe transportation. Failure to do so may result in accidents during handling and transit, including leaking batteries or damaged cells.

Safety Tips for Transporting Li-ion Batteries

So, what can you do to reduce risk when you’re on the road? Here’s some simple things you can do to control fire risk with your batteries when they’re in transit.

State of Charge 

Lithium-ion batteries are most unstable when they’re in a fully charged state. When batteries are below 50% charge, they pose much less risk due to the decreased risk of thermal runaway and explosion from heat exposure. Consider transporting your batteries at a lower state of charge. 

Battery Size 

Your battery size can also influence how you transport your cells. Larger batteries may require a temperature-controlled environment rather than a standard battery transport container. 

Inspections

When transporting your batteries, inspect them before putting them on the road. Look for aged batteries, swelling, leaking or otherwise damaged cells which may pose a risk when transported, charged or otherwise used.

Avoid Water and Moisture

If you check your safety data sheet for your lithium-ion batteries, there are many conditions that you must avoid to ensure safety with your cells. One of these is ensuring batteries aren’t affected by rain, water or excessive humidity. By storing batteries in a suitable transport unit, you can avoid this potentially hazardous situation.

Incompatibilities with Other Stored Materials

Any type of dangerous goods, including a lithium-ion battery, will be incompatible with other substances. To mitigate this risk, only store lithium-ion batteries together during short or long-term storage and transport. Isolate from any sources of heat or ignition as well as incompatible materials and dangerous goods. See section 10 in your SDS for stability and reactivity information.

Monitoring

During transport, especially over long distances, there may be limited monitoring of the conditions in which the batteries are stored. Exposure to extreme temperatures or other unfavorable conditions could increase the risk of battery malfunctions.

Heat and Temperature Fluctuations

As you already be aware, heat, direct sunlight and extreme temperatures are environmental conditions that you want to avoid exposing your lithium-ion batteries to. This is particularly important when you’re considering the transport of lithium-ion batteries by road.

Batteries must be kept at a specific temperature range in order for them to operate safely. However, if they are being transported – for example, in the back of a ute with no protection to a remote work site – they are exposed to extreme temperatures that could spark a fire.

By ensuring Li-on cells are kept at or below their safe temperature, you can reduce the risk of thermal runaway and fire.

IMPORTANT: Lithium-ion batteries should be kept at room temperature (ideally around 15-17°C, but check your batteries for the recommended temperature limits) in a ventilated, dry, protected location that is not in direct sunlight.

Impact Damage

When batteries (or any chemicals, for that matter) are being handled and moved, there is a chance that the substance could suffer from impact damage.

While a spill of chemicals in the back of a truck is a dangerous situation, the damage of lithium-ion batteries can also cause a serious incident for those travelling in and around the work vehicle.

Mechanical abuse, such as batteries being dropped, punctured or hit with force, can create thermal runaway, which can then spread to the other cells being transported. Protection for the cells — from vehicle impact or handling errors — is vital for lithium-ion battery safety.

IMPORTANT: Never use, charge or discharge lithium-ion batteries that are damaged, defective or deformed. Always check the batteries before transporting them and follow the appropriate protocol for safe Li-ion battery waste disposal.

Waste Disposal Considerations for Lithium-ion Batteries

It’s a safe bet that at some stage in your work life, you will have to deal with a damaged or volatile battery. However, there are safety precautions you need to take when managing a damaged lithium-ion battery.

Never touch a cell without the proper personal protective equipment and ensure the battery is isolated from other staff during the process. Your safety data sheet will include information about suitable protection, such as PVC gloves.

Liase with your local waste authority who can advise on the best procedures for lithium-ion battery waste removals.

REMEMBER: Do not incinerate batteries or throw in your usual waste bin. Dispose of lithium-ion batteries in accordance with appropriate local regulations. Recycle batteries when possible.

How Can Battery Transport Reduce Lithium-ion Fire Risk?

By transporting your charged batteries – or even your damaged batteries – in a dedicated transport unit, you can help control many of the risks associated with these cells.

Without sufficient protection on the road, batteries can be exposed to further risks that could spark thermal runaway, battery leaks or fire.

You can decrease risk if handling, storage and transport of batteries is done in a methodical and careful manner. Engineering controls such as transport units, offer a range of safety features.

Storemasta battery transport units offer safety features including:

• Heavy duty 3mm steel construction
• Lined with 15mm cement sheet
• Fitted with aerosol canister fire suppression system
• Intumescent lid seal
• Venting fitted with arrestor
• Heavy duty over centre latch with padlocking
• Visual and auditory alarm

REMEMBER: By choosing a transport unit, you can reduce hazards— and adhere to the recommendations of the safety data sheet and manufacturer’s instructions.

Lithium-ion Battery Transport – How To Control Risk

To learn more about assessing and controlling risk, we recommend reading our eBook The Risk Assessment Process for Workplace Batteries. This free guide will take you through the steps of identifying hazards with your lithium-ion and lead acid batteries. Grab your copy today to learn more about lithium-ion battery safety.