What safety regulations will apply to the transport of lithium-ion batteries in 2025?

The transport of lithium-ion batteries will become increasingly complex by 2025 due to stricter international regulations and growing demand for safe transport solutions. Whether you are shipping military drones, defence equipment or industrial systems, a thorough understanding of safety regulations is essential to ensure compliance and minimise risks. This guide provides a comprehensive overview of all relevant regulations, from UN codes to practical packaging requirements, enabling you to transport your lithium batteries in full compliance.

Which UN codes apply to lithium-ion batteries in 2025?

The classification of lithium-ion batteries for transport is based on specific UN codes that determine which safety measures apply. These codes are crucial for the correct identification and handling of your battery shipments. UN3480 applies to lithium-ion batteries shipped as standalone goods. This covers loose batteries, battery packs and rechargeable batteries not installed in equipment. The strictest packaging and transport requirements apply to this category, including special documentation and labelling. UN3481 is used when lithium-ion batteries are shipped together with equipment but are not installed in the device. Think of a drone case containing loose spare batteries alongside the device. This classification has less stringent requirements than UN3480, but still requires specific packaging measures. For batteries permanently installed in devices, such as in defence drones or industrial systems, UN3091 applies. This code has the least restrictive requirements, but still requires correct documentation and packaging to prevent damage during transport.

UN-Code	Application	Packaging Group	Special requirements
UN3480	Replaceable lithium-ion batteries	II	Charged to a maximum of 30%, special packaging
UN3481	Batteries with equipment	II	Short-circuit protection
UN3091	Batteries in equipment	II	The device must be switched off

ADR and IATA regulations for lithium battery transport

For road transport within Europe, the ADR regulations (European Agreement concerning the International Carriage of Dangerous Goods by Road) apply. These regulations specify how lithium battery transport by road must be carried out and what documentation is required. The ADR regulations for 2025 contain important updates regarding maximum quantities per transport unit and required training for drivers. Simplified procedures apply to small quantities of lithium-ion batteries (below certain thresholds), but larger shipments require full ADR compliance. For air transport, the IATA Dangerous Goods Regulations apply. These international standards have been further tightened in 2025, particularly for passenger aircraft where the transport of lithium batteries is subject to strict restrictions. Cargo transport offers more flexibility, but requires specialised packaging and documentation. Key changes in 2025 relate to State of Charge (SoC) limits and improved testing procedures for packaging. Batteries may be charged to a maximum of 30% for air transport, whilst different percentages may apply for road transport depending on the specific circumstances.

Documentation requirements by mode of transport

• Road transport: ADR transport document, driver safety instructions
• Air transport: Shipper’s Declaration, IATA-compliant labelling
• Sea transport: IMDG documentation, container packing certificate
• Rail transport: RID-compliant documents, wagon loading list

Packaging requirements and certification for battery shipment

UN-certified packaging is mandatory for all commercial lithium battery shipments. This packaging must have passed specific tests and bear a UN mark confirming its suitability for hazardous materials. For defence and industrial applications, such as new defence drones or military equipment, customised packaging solutions are often required that meet both UN requirements and military standards. These combine robust protection with compliance with transport regulations. Special attention must be paid to transport cases for drones, which often contain multiple batteries. These drone cases must have individual battery compartments that prevent short circuits and provide sufficient insulation. IP 67 protection is often required for military applications to withstand weather conditions and extreme environments. Labelling must comply with IATA and ADR standards, including:

• UN number and proper shipping name
• Lithium battery labels with warning symbols
• Handling labels for correct orientation
• Emergency contact information

Challenges in defence and industrial battery transport

The transport of lithium-ion batteries in military drones and defence equipment presents unique challenges. These systems often require higher energy densities and must withstand extreme operational conditions, necessitating specific transport measures. Defence drones often contain multiple battery systems with different capacities and chemical compositions. This requires specialised transport cases that can safely accommodate different battery types without them affecting one another. Military standards such as MIL-STD-810 impose additional requirements on packaging for defence applications. These go beyond standard UN requirements and include resistance to shocks, vibrations, temperature fluctuations and humidity that may occur in military environments. For industrial applications, logistical considerations often play a key role. Reusable transport solutions are becoming increasingly popular to reduce costs and meet sustainability targets, making tracking and return logistics essential.

Specific considerations for defence transport

• Classification levels and security requirements
• International transport restrictions and export licences
• Special handling procedures at military bases
• Backup power requirements during transport

Practical checklist for safe lithium battery shipping

A systematic approach is essential for compliant lithium battery transport. This checklist helps you carry out all critical steps correctly and avoid common mistakes. Preparation and classification:

1. Determine the correct UN code (UN3480, UN3481, or UN3091)
2. Check battery specifications and State of Charge
3. Verify mode of transport and applicable regulations
4. Ensure correct documentation and certificates

Packaging and protection:

1. Use only UN-certified packaging
2. Prevent short circuits by insulating contact points
3. Ensure adequate shock absorption and vibration damping
4. Check IP protection rating if required

Labelling and documentation:

1. Affix correct UN labels and warning symbols
2. Include handling instructions for carriers
3. Provide emergency contact information
4. Check the completeness of transport documents

Final check:

1. Verify packaging integrity and sealing
2. Test tracking systems where applicable
3. Confirm carrier certification for dangerous goods
4. Document all steps for audit trail

By following this systematic approach, you ensure that your lithium-ion battery shipments comply with all relevant safety regulations for 2025. Whether it concerns defence drones, industrial equipment or other critical systems, proper preparation and execution are essential for safe and compliant shipment.

Choose certainty for lithium battery transport

Are you ready to eliminate risks and ensure full compliance when transporting lithium-ion batteries? Contact Faes today for bespoke advice and certified packaging solutions that meet all requirements for 2025. Our specialists will help you optimise processes, prevent errors and ensure safety. Discover how to make your transport flows safer, more efficient and future-proof.

How often do regulations and UN codes for lithium-ion battery transport change?

International regulations are typically reviewed every two years, with minor updates that may be implemented annually. It is essential to monitor quarterly updates via official IATA, ADR and IMDG channels, particularly as changes are often announced only a few months in advance and have an immediate impact on compliance.

What are the costs of non-compliance in lithium battery transport?

Non-compliance can lead to substantial fines (€5,000–€50,000 per violation), transport delays, seizure of goods and even criminal prosecution in the case of serious violations. In addition, insurance claims may be rejected and companies may lose their transport licences, which threatens operational continuity.

How can I check that my carriers have the correct certification for lithium batteries?

Verify that carriers hold valid ADR/IATA Dangerous Goods certificates and request copies of driver training records. Check their UN packaging certificates and ask for their incident history. Conduct regular audits and ensure contractual compliance clauses with a clear allocation of liability.

What insurance aspects should I consider when transporting lithium batteries?

Standard transport insurance policies often do not cover lithium battery-related damage. Ensure you have specialist dangerous goods insurance that covers thermal runaway, fire and environmental damage. Document all compliance measures carefully, as insurers often require proof of correct procedures when settling claims.

How do I deal with damaged lithium batteries during transport?

Stop transport immediately and isolate the battery in a safe, ventilated area. Contact the emergency services and the battery manufacturer for specific instructions. Never use water on lithium-ion fires – use Class D fire extinguishers. Document all incidents for reporting to the relevant authorities.

What are the specific requirements for the international shipment of defence batteries?

Defence batteries often require export licences and ITAR/EAR compliance in addition to standard UN requirements. Check destination country restrictions and dual-use classifications. Use accredited freight forwarders with security clearance and ensure end-user certificates are in place. Some countries have complete import bans on military battery systems.

How can I correctly measure and document the State of Charge (SoC) of batteries?

Use calibrated multimeters or battery analysers to measure voltage and calculate SoC according to manufacturer specifications. Document measurements with a timestamp and operator identification. Special measurement protocols may apply for defence applications. Retain measurement reports for at least two years for audit purposes and compliance verification.