Lithium-ion batteries have become a central component of the energy revolution. Whether it's electric mobility, stationary energy storage systems or industrial applications — demand is constantly increasing. However, it also increases complexity in transportation. Batteries are considered dangerous goods and their transportation is subject to strict international regulations.

Increasing volumes, larger battery capacities and new fields of application mean that regulatory requirements are constantly evolving. For logistics companies, this means: more responsibility, higher safety standards and more precise documentation.

Why lithium batteries are considered particularly risky

Lithium-ion batteries store large amounts of energy in a small space. Mechanical damage, production errors, or improper packaging can result in short circuits. In the worst case, a so-called “thermal runaway” occurs — an uncontrolled chain reaction with a risk of fire or explosion.

The risk increases, particularly in the case of collective transport, damaged returns or recycling transport. Batteries are therefore subject to clearly defined dangerous goods classes.

An overview of international regulations

Depending on the mode of transport, there are different rules:

• ADR (Accord européen relatif au transport international des marchandises dangereuses par route) for road transport
• RID (Règlement concernant le transport international ferroviaire des marchandises dangereuses) for rail
• IMDG code (International Maritime Dangerous Goods Code) for maritime transport
• IATA-DGR (International Air Transport Association — Dangerous Goods Regulations) for air freight

These regulations define, among other things:

• UN numbers (e.g. UN 3480 for lithium-ion batteries)
• packaging instructions
• Labeling requirements
• quantity limits
• Documentation requirements

As the market penetration of battery storage systems increases, these regulations are regularly amended.

New developments in ADR

The latest ADR developments respond to two key trends:

1. Larger battery systems
   Stationary energy storage systems or battery packs for e-vehicles often exceed classic packaging dimensions. Special rules apply here.
2. Defective or damaged batteries
   For so-called “critical” or “damaged” batteries, there are stricter packaging and transport requirements, including fire-retardant materials and individual packaging.

There are also stricter requirements for training, equipment and documentation.

Increasing volumes are changing the reality of transport

With the expansion of electric mobility, not only is the number of new battery products increasing, but also the quantity:

• Transport of spare parts
• returns
• second-life systems
• recycling transports

New challenges arise, particularly in the area of return and recycling logistics. Damaged or aged batteries are harder to assess and require special safety measures.

Safety starts with packaging

Packaging plays a central role. The following are mandatory:

• UN certified packaging
• Upholstery and fixation material
• Short circuit protection
• Temperature monitoring, if necessary

There are additional requirements in maritime transport, such as specific congestion and separation regulations.

Modern sensors and telematics can help to identify temperature deviations or shocks at an early stage.

Infrastructure and storage

Not only the transport itself, but also interim storage and transhipment are critical. Storage areas must:

• Be suitable for fire technology
• Keep separate zones for damaged batteries
• Define clear emergency plans

Complexity is increasing, particularly in the case of collective transports or distribution centers.

Insurance and liability issues

As risks increase, insurers are also responding sensitively. Premiums and coverage conditions may change, particularly in the case of high-voltage batteries or international transport chains.

Transparent documentation and verifiable security processes are therefore increasingly becoming a competitive factor.

Multimodal dangerous goods chains

Battery transport is often multimodal: road — port — sea freight — road. Each interface requires correct documentation and coordination between regulations.

Errors in the declaration can lead to rejections at port or delays in transhipment. Harmonizing processes is therefore crucial.