General questions about batteries
The nominal energy is indicated directly on newer batteries. If this is not the case, the capacity of a battery can be quickly calculated.
Nominal energy in Wh = capacity in Ah x voltage in V.
The regulations for shipping are very extensive. National regulations of the BAM (Federal Institute for Materials Management), the GüKG (Road Haulage Act) and the KrWG (Circular Economy Act) apply. The international regulations can be found in the ADR.
These regulations affect all parties involved in the supply chain, including senders (and their clients), shippers, packers, drivers, unloaders and recipients.
Read our blog post with a flowchart on this topic:
https://www.lion-care.com/aktuelles/blog/transportvorschriften-regeln-und-sicherheitsmassnahmen
The first rough distinction concerns the type of battery. Is it lithium-ion cells or batteries (1), lithium-metal cells or batteries (2) or lithium hybrid cells or batteries (3).
The following is crucial:
- the nominal energy in watt hours (Wh)
From a nominal energy value of more than 100 Wh, batteries are classified as class 9 hazardous goods and are subject to the provisions of the ADR. - the lithium content in grams
The limit here is 2g per battery.
Smartphone battery approx. 0.2-0.3g, AA lithium battery approx. 1g, lithium button cells (car keys) or photo batteries e.g. CR2 - both the nominal energy in Wh and the lithium content in grams
Unfortunately, there is no general answer to this question. If there is a possibility/risk that a fire or explosion could occur during the transport of a defective or damaged battery, you should choose a transport container that is designed to prevent this.
The classification is usually done by a high-voltage technician.
However, these transports are subject to strict conditions and many regulations. For this purpose, it is imperative to observe the relevant requirements of the ADR.
Fire Blankets
Here, too, the size and the fire behavior of the object are crucial. An e-bike battery reaches different temperatures than the fire of an electric car.
When an electric vehicle catches fire, temperatures of up to 1,000°C can be reached – and even peaks of 1,200°C for a short time.
Due to the different fire behavior, it is not possible to make an accurate statement about the temperatures that will arise and the duration of the fire.
In the event of a fire and the active use of the blanket, no. We strongly advise against it. Firstly, the extreme temperatures can cause damage to the material that cannot be reliably assessed by laypersons. Secondly, fires produce toxic gases that are harmful to health and can adhere to the material.
The ceiling can be used repeatedly for protection if there is no damage.
The right size of fire blanket depends largely on the size of the burning object and its size. An e-scooter requires a smaller blanket than an e-car or a forklift.
Roughly measure how large the blanket needs to be so that it still lies flat on the ground around the object, with a 1-2m overhang. Don't forget to take the height into account (e.g. SUV). This is the only way to ensure that toxic gases remain under the blanket for the most part and that flames have no chance of igniting the area around the source of the fire.
Here are some examples of common sizes:
Automobiles:
Larger vehicles such as station wagons, SUVs, sedans, forklifts: The fire blanket should be at least 6x8 meters (taking into account the height of the vehicle).
Medium-sized vehicles: The fire blanket should be at least 5x6m in size.
Smaller electric vehicles, e.g. warehouse robots: The fire blanket should be at least 3x4m in size.
Appliances with batteries, such as cordless screwdrivers, garden tools: The fire blanket should be at least 1.5x1.5m in size.
Cell phones and laptops: The fire blanket should be at least 1.5x1.5m in size.
There are also differences in the materials used. The fire blankets differ, for example, in their composition, material thickness and temperature resistance. This is crucial, for example, if the blankets are to be used directly on batteries, not installed, as in vehicles.
When making your purchase, don't forget the weight of the blankets. A large blanket can quickly weigh 25-45 kg. Here, for example, there is the option of storing it in a trolley.
Unfortunately not. Fires caused by lithium-ion batteries are chemical fires that are independent of oxygen. They continue to burn even if they are deprived of oxygen or if you try to extinguish them with water as you would conventionally.
Nevertheless, the fire brigade uses water to cool the burning battery. Even after hours, a battery can ignite again.
The only thing that helps here is a controlled burn-off and fire containment to prevent the fire from spreading to the surrounding area due to high temperatures or escaping flames.
The name “fire blanket” is common, but misleading. These special, high-temperature-resistant blankets do not extinguish battery fires. What works on the grill does not work on lithium batteries.
With fire blankets, the name says it all: they contain the fire and thus also the damage, giving you time to alert the local fire brigade, who will decide on further fire-fighting measures.
Find out more about this topic in our blog articles:
https://www.lion-care.com/aktuelles/blog/brandbekaempfungsstrategien-fuer-elektrofahrzeuge
https://www.lion-care.com/aktuelles/blog/akku-braende-bekaempfen-kuehlen-kontrollieren-oder-abwarten
The German DIN SPEC 91489 provides clarity for stakeholders in various industries.
DIN SPEC 91489 contains several requirements for fire-retardant ceilings, the most important of which are listed below:
- General requirements
Properties such as loops, size of the blanket, storage, etc. are mentioned. - Thermal resistance
The DIN SPEC requires a minimum ISO13591-1 classification B. However, the Fire Isolator fire blankets have a higher (the highest) classification: A1. - Mechanical stability
Resistance to cutting, stability of loops, etc. - Electrostatic charge
- Protection against electric shock
- Chemical resistance
- Markings
- Manufacturer information
- Minimum content of the test report
- Training for use by first responders
DIN SPEC 91489 requires that fire blankets can be used quickly and easily by two trained responders wearing personal protective equipment and breathing apparatus.
In the event of a battery fire, such a blanket provides valuable time to alert the fire department and prevent the flames from spreading. This applies to all possible uses, be it a cell phone, a laptop, an e-scooter, a factory robot or an electric car.
This question will be answered by the local fire department, because they are always to be alerted and they initiate further fire-fighting measures.
It is highly dangerous to let a burning electric car burn out under such a blanket and wait until it is all over. A battery fire could last for days and reignite repeatedly. Among other things, the fire produces toxic gases that must be contained as quickly as possible.
Storage- & Transport-Boxes
To date, there are no legal requirements for the storage of lithium-ion batteries, which does not mean that they should be stored without suitable protective measures.
It is best to check with your insurer to find out which measures they recognize as suitable in the event of a claim.
For example, a suitable box could already be recognized as spatial separation.
A rough overview can be found in this VDS publication from the GDV:
https://shop. vds.de/download/vds-3103/ccb1d439-ad9d-47cb-a2b1-ace23e155610
Please also read our blog article on this topic:
https://www.lion-care.com/aktuelles/blog/lithium-ionen-akkus-sicherer-umgang-und-richtige-lagerung
That depends on various factors that need to be considered:
- size of the battery(ies)
- condition (e.g. non-critical, defective, critically defective or prototype)
- power
Transport boxes are available in many different sizes and specifications. The packaging group for which the box is suitable is indicated for each product.
Find out more in our blog article:
https://www.lion-care.com/aktuelles/blog/transportvorschriften-regeln-und-sicherheitsmassnahmen
Even if the batteries are not critical, remember to protect them from shocks and to order appropriate filling material if it is not already included in the box.
Yes. Should a battery reach a critical state and cause a fire, separating the batteries will prevent the fire from spreading and multiplying.
Generally, the insulation and protection material should line all sides of the container. The batteries are stored between individual layers.
We also have containers in our program that already have the protective material integrated into the outer wall. No further protective layer is necessary here.
The technical principles for storage and transportation solutions are very similar. The transport boxes are also subjected to extensive tests in accordance with ADR (drop test, fire test, etc.) to confirm compliance with the ADR regulations. The packaging regulations are extensive and regulated by law.
There are currently no comparable regulations for storage. Nevertheless, manufacturers of storage boxes regularly carry out appropriate tests.
The right container depends on the type and size of the battery to be shipped or stored.
If you want to learn more about battery storage and transportation, you will find the answers in our blog articles:
https://www.lion-care.com/aktuelles/blog/transportvorschriften-regeln-und-sicherheitsmassnahmen
https://www.lion-care.com/aktuelles/blog/lithium-ionen-akkus-sicherer-umgang-und-richtige-lagerung
The transportation of batteries is subject to ADR regulations.
The number, size and weight, energy density and condition of the batteries are crucial parameters for finding a suitable transport container for lithium-ion batteries. The selection process is complex and should be carried out by appropriately trained personnel. We have a trained hazardous materials officer on our team. Please feel free to contact us.
Plastic containers are cheaper but not as durable as metal containers. They are suitable, for example, for non-critical batteries, defective batteries, prototypes and end-of-life batteries. They can be used for both storage and transportation.
Metal containers are required, for example, when dealing with critically defective batteries.
The exact packaging instructions for these cases can be found in the ADR or by consulting a certified hazardous materials specialist.
Battery Cabinets
Standard security cabinets are designed for indoor use, so they cannot be used outdoors.
The fire protection panels installed in the cabinets contain gypsum, which contains a lot of water, which expands when frozen. This deforms the panels. It can no longer be guaranteed that such a cabinet is still sealed or can withstand an explosion.
If you already have a suitable room that is structurally fire-resistant, then you do not necessarily need a safety cabinet to contain the fire.
However, please do not forget that the damage caused by a battery fire involves immense and also toxic contamination, the disposal of which can quickly lead to high costs.
In addition, you may not be able to continue working as usual until the damage has been finally repaired - depending on the location of the damage.
Filling Materials
Vermiculite is a 100% mineral natural product and is very well suited as a filling material for packaging in accordance with the dangerous goods regulation.
It absorbs leaking liquids, protects against shocks, is non-flammable and non-conductive.
PyroBubbles are a filler made of purified glass. They are non-flammable, electrically conductive and offer a high level of protection against shocks and vibrations. They contain a fire by melting around the source of the fire and forming a cocoon.
https://www.lion-care.com/aktuelles/blog/pyrobubbles-der-fuellstoff-fuer-ihre-verpackungen
Test Bench Containers
Test stand containers are custom-made to customer specifications (e.g. cable glands) in order to be able to test the desired number of batteries under the given test requirements.
Charging containers
To date, there are no legal requirements for the storage of lithium-ion batteries, which does not mean that they should be stored without suitable protective measures.
It is best to check with your insurer to find out which measures they recognize as suitable in the event of a claim.
For example, a suitable box could already be recognized as spatial separation.
A rough overview can be found in this VDS publication from the GDV:
https://shop. vds.de/download/vds-3103/ccb1d439-ad9d-47cb-a2b1-ace23e155610
Please also read our blog article on this topic:
https://www.lion-care.com/aktuelles/blog/lithium-ionen-akkus-sicherer-umgang-und-richtige-lagerung
Fire extinguishers
Air freight transport of lithium-ion batteries
Strict dangerous goods regulations apply to air freight transport of a lithium-ion battery.
These are the most important points you must observe:
- Classification as dangerous goods (Class 9): Batteries over 100 Wh must always be classified as Class 9 dangerous goods and are subject to the comprehensive dangerous goods regulations of the IATA DGR and ICAO TI.
- Air freight only approval: Batteries above 100 Wh may only be shipped on cargo aircraft, not passenger aircraft. Freight forwarders do not handle dangerous goods shipments for private individuals. Therefore, it is often advisable to purchase a new battery locally if, for example, you move abroad and wish to take your bicycle or golf trolley battery with you.
- Maximum state of charge 30 %: Since April 2016, lithium-ion batteries (UN 3480) as standalone batteries may only be transported with a state of charge not exceeding 30 %. From 2026, this requirement will also apply to batteries installed in equipment.
- UN test summary (UN 38.3 test): A test summary must be available and presented upon request throughout the supply chain. This confirms that the battery has passed the UN transport safety tests.
- Packing instructions:
- Requirements according to Packing Instruction PI 965 Part I A (without equipment).
- The packaging must be UN-certified, shock-resistant, and leak-proof.
- Each package must be clearly marked with the appropriate dangerous goods label, UN number (UN 3480 for standalone batteries, UN 3481 for batteries packed with or in equipment), and any additional labels.
- Accompanying documents: A dangerous goods transport document containing all relevant information (e.g., UN number, proper shipping name, class, packing instruction, shipper/consignee, state of charge) must accompany the shipment.
- Quantity limitations: For larger batteries, additional restrictions apply to the permissible net quantity per package (usually 35 kg per package).
- Defective or damaged batteries: Must not be transported by air and must be disposed of separately.
- Training requirement: As a shipping company, you are required to employ trained personnel for marking, packing, and documentation. The training (two days) includes an examination.
Additional notes:
- Many express and courier services refuse to transport batteries of this size or accept them only under very limited conditions.
- Compliance with and proof of the state-of-charge limit may already be required for current shipments.
Conclusion: You must arrange transport through an experienced dangerous goods forwarder, fulfill all documentation and marking requirements, reduce the state of charge to a maximum of 30 %, provide the UN 38.3 test summary, and pack the battery according to PI 965 Part I A. Otherwise, you face legal consequences, fines, or loss of insurance coverage.