When you ship batteries, you must use caution & overpack labels of lithium battery to comply with IATA Section 11. These labels identify lithium batteries in transit, reduce risks, and support safety. With recorded incidents—113 over 19 years, mainly from improper packaging—shipping lithium batteries safely demands strict label placement and clear, durable markings.
Key Takeaways
Always apply CAUTION labels on lithium battery packages to meet safety rules and alert handlers about hazards during shipping.
Use overpack labels when combining multiple packages, making sure all labels are visible and duplicated if needed to avoid shipment delays or fines.
Follow packaging, labeling, and documentation rules carefully, train your staff, and check regulations often to ensure safe and compliant lithium battery shipping.
Part 1: CAUTION Labels & Lithium Battery Packing Instructions
1.1 CAUTION Label Purpose
You must use CAUTION & Overpack labels of lithium battery to meet the strict requirements for shipping lithium batteries by air. These labels play a critical role in identifying packages that contain lithium-ion battery products. They alert handlers and carriers to the presence of lithium, which is classified as a hazardous material under dangerous goods regulations. CAUTION labels help prevent accidents by ensuring that everyone in the supply chain recognizes the potential hazard and follows the correct safety guidelines.
Note: CAUTION labels are not just stickers. They are a legal requirement under IATA Section 11 and must be used for lithium batteries that are exempt from Class 9 but still regulated. This includes most lithium battery packs shipped in small quantities.
1.2 When to Use CAUTION Labels
You need to apply CAUTION & overpack labels of lithium battery when shipping lithium batteries that fall under Section II of Packing Instructions 965, 966, or 967. These instructions cover different scenarios:
PI 965: Loose lithium-ion cells and battery packs (UN3480)
PI 966: Lithium-ion batteries installed in equipment
PI 967: Lithium-ion batteries packed with equipment (UN3481)
CAUTION labels are mandatory for shipments under Section II, which covers small quantities of lithium batteries that do not require full Class 9 hazardous material labeling. However, these batteries still pose a hazard and must comply with all safety and labeling requirements. You must also use the CAUTION label if you ship lithium batteries as dangerous goods under Section IA or IB, along with the Class 9 and Cargo Aircraft Only labels.
Regulatory Aspect | Details / Numerical Examples |
|---|---|
Classification | Lithium batteries divided into Non-Class 9 (small quantities, limited lithium content) and Class 9 hazardous materials (larger sizes/volumes). |
Packaging Instructions | PI 965: loose Li-ion cells/packs; PI 966: installed in equipment; PI 967: packed with equipment. |
Labeling Requirements | CAUTION label mandatory on all lithium battery shipments under Sections II, IA, IB of PI 965. |
Label Dimensions | CAUTION label: approx. 120mm x 115mm; Cargo Aircraft Only label: approx. 300mm x 300mm; Class 9 label: approx. 100mm x 100mm. |
State-of-Charge (SoC) | Max 30% SoC for PI 965 Sections II, IA, IB. No SoC limit for batteries packed with/contained in equipment. |
Passenger Aircraft Ban | Lithium batteries under Sections II, IA, IB forbidden as cargo on passenger aircraft. |
Lithium Content | Lithium content (g) = Rated capacity (Ah) × 0.3; Example: 5Ah battery, 4 cells = 6g lithium, 72Wh. |
Shipment Restrictions | Only one Section II package per consignment; batteries must be separated from other cargo. |
Documentation | Shipping documents must include consignor name/address, date, phone number, UN number, and weight. |
1.3 Label Placement
You must place the CAUTION & overpack labels of lithium battery on the outside surface of each package. The label must be clearly visible and not covered by any other markings or tape. For best results, position the label on the largest flat surface of the shipping carton. If you use an overpack, repeat all required labels and markings on the outermost layer.
Ensure the CAUTION label is not folded over edges or corners.
Do not place the label on the bottom of the package.
If the package contains multiple batteries, make sure the label is large enough to be seen from a distance.
Tip: Use labels with contrasting colors and standardized font sizes to improve visibility and reduce the risk of mishandling during shipping.
1.4 Required Markings
Every CAUTION label must include specific information to comply with dangerous goods regulations:
The UN lithium battery mark (e.g., UN3480 or UN3481)
A telephone number for additional information about the shipment
A clear statement that the package contains lithium batteries and must be handled with care
Instructions in case the package is damaged
The standard CAUTION label size is approximately 120mm x 115mm. You must use durable, weather-resistant materials for the label to ensure it remains legible throughout the transportation of lithium-ion batteries.
Example of Required Markings:
CAUTION
Lithium ion batteries in compliance with Section II of PI965
Handle with care. Flammable hazard if damaged.
For more information, call: [Your Phone Number]
UN3480
1.5 Compliance Tips
To achieve full compliance and safety when shipping lithium batteries, follow these best practices:
Always check the latest IATA dangerous goods regulations before shipping.
Use only approved packaging that meets drop test and short circuit prevention standards.
Ensure batteries are separated to prevent contact and accidental activation.
Never ship defective or damaged batteries.
Limit the state-of-charge to 30% for loose lithium-ion battery shipments under PI 965.
Include all required documentation, such as the dangerous goods declaration, with each shipment.
Train your staff regularly on lithium battery packing instructions and labeling guidelines.
Callout: Proper labeling and packaging requirements protect your business, your customers, and the entire supply chain. They also help you avoid costly delays, fines, or rejected shipments.
If you want to learn more about sustainable battery practices, visit our sustainability approach. For information on conflict minerals, see our conflict minerals statement.
Part 2: Overpack Labels, Shipping, and Safety
2.1 Overpack Label Use
You use an overpack label when you consolidate multiple packages containing lithium batteries into a single handling unit, such as a pallet wrapped in plastic or a large outer box. Overpacks simplify the shipping process by allowing you to move several packages together, but they do not replace the need for each inner package to meet all packaging and labeling requirements. According to IATA Dangerous Goods Regulations, you must apply an overpack label if any required marks or labels on the inner packages are not visible from the outside. This ensures that everyone handling the shipment recognizes the presence of lithium batteries and follows the correct safety procedures.
Note: Overpack labels are mandatory for palletized cargo containing one or more boxes with lithium batteries. You must print the label in color, trim it to fit around the red border, and affix both the overpack label and the UN label to the outer wrapping.
Overpacks play a vital role in the transportation of lithium-ion batteries for industries such as medical, robotics, security, infrastructure, consumer electronics, and industrial sectors. Proper use of overpack labels helps you maintain compliance with international regulations and supports safe transport.
2.2 Overpack Label Placement
You must place the overpack label on the outside of the overpack, ensuring it is clearly visible and not covered by straps, shrink wrap, or other packaging materials. The label should be on a flat surface and oriented so that handlers can read it easily. If the overpack is large, such as a pallet, you should place the label on at least two opposite sides to maximize visibility.
Labels must be durable, legible, and not obstructed.
The word “OVERPACK” must appear in letters at least 12 mm high.
Lithium battery marks must be rectangular or square with hatched red edging, measuring at least 100 x 100 mm, or 100 x 70 mm for small packages.
Specification Aspect | Requirement Details |
|---|---|
Label Visibility | Lithium battery marks must be clearly visible through the overpack or reproduced on the outside. |
Overpack Marking | The word “OVERPACK” must be marked on the overpack with letters at least 12 mm (0.47 inches) high. |
Label Size and Design | Lithium battery marks must be rectangular or square with hatched red edging; minimum size 100×100 mm, or 100×70 mm for small packages. Symbols and letters must be black on white or contrasting background. |
Securing Packages in Overpack | Packages must be secured inside the overpack without impairing their intended function. |
Compliance with Testing | Batteries must comply with UN Manual of Tests and Criteria sub-section 38.3 for safe transport. |
Tip: Always check that all required labels and marks are visible before shipping lithium batteries. Non-compliance can result in fines or shipment rejection.
2.3 Duplicating Marks
You must duplicate all required marks and labels on the outside of the overpack if they are not visible through the outer packaging. This includes the lithium battery mark, UN number, and any other dangerous goods labels. For overpacks larger than 1.8 m³, regulations require you to place duplicate hazard labels on at least two sides or ends. This practice ensures that handlers and inspectors can identify the hazard from multiple angles without moving or lifting the overpack.
Duplicate marks help prevent confusion and support compliance with 49 CFR § 172.406(e).
Carriers may reject shipments if required markings are not visible.
Duplicating marks reduces the risk of mishandling and improves overall safety during shipping.
2.4 Shipping Safety Measures
You must follow strict safety measures when shipping lithium batteries in overpacks. These measures protect your cargo, your team, and the supply chain from the risks associated with lithium, such as fire or short circuits.
Use only packaging that meets the UN Manual of Tests and Criteria Section 38.3.
Secure all batteries inside the overpack to prevent movement or damage.
Protect battery terminals to prevent short circuits.
Never ship defective, damaged, or recalled batteries unless authorized by the relevant authorities.
Assess fire hazards and ensure that all batteries have passed required tests. Manufacturers must provide test summaries to demonstrate compliance.
Follow all U.S. Department of Transportation Hazardous Materials Regulations and IATA Dangerous Goods Regulations for shipping lithium batteries.
Practical examples include pallets with multiple packages secured by plastic strips or shrink film, and large boxes or crates used as outer protective packaging. Overpacks must always display the overpack label and all other relevant dangerous goods labels, especially when inner package markings are not visible. These steps align with safety guidelines and help you achieve safe transport of lithium-ion battery products.
Callout: Failure to comply with safety requirements can result in fines or criminal prosecution. Always consult the latest regulations and seek expert advice for custom battery solutions.
2.5 Common Mistakes
Many shippers make errors when applying overpack labels during shipping lithium batteries. One common mistake is failing to declare a pallet as an overpack, even when all individual package labels are visible. This oversight can lead to shipment rejection and regulatory frustration. Another frequent error involves improper placement of overpack markings on pallets secured with straps or shrink wrap, making the labels hard to see.
You can avoid these mistakes by:
Treating every pallet or consolidated package as an overpack when required.
Ensuring all overpack labels and marks are visible and legible.
Reviewing the latest labeling guidelines and regulations before each shipment.
Training your staff on proper labeling and documentation procedures.
Quick Reference Checklist for CAUTION & Overpack Labels of Lithium Battery:
Confirm all inner packages meet lithium battery packaging and labeling requirements.
Apply CAUTION labels to each package as required.
Use overpack labels when consolidating packages and ensure all marks are visible.
Duplicate all required marks on the outside of the overpack if not visible.
Secure batteries to prevent movement and protect terminals.
Never ship defective or damaged batteries.
Maintain documentation for compliance and inspection.
Regularly review regulations and update your shipping procedures.
For more information on sustainable battery practices, visit our sustainability approach. If you need custom lithium battery solutions or have questions about compliance, consult our experts.
You protect your business and ensure global compliance when you label lithium batteries correctly.
Apply CAUTION and Overpack labels to all lithium batteries, including NMC Lithium battery, LCO Lithium battery, LMO Lithium battery, and LiFePO4 Lithium battery.
Use visible marks, accurate UN numbers, and required documentation for every shipment.
Train staff on lithium battery handling, packaging, and emergency response.
Review lithium battery regulations often, as updates from IATA and DOT affect batteries in medical, robotics, security, infrastructure, consumer electronics, and industrial sectors.
Prevent shipment rejection, fines, and safety incidents by following best practices for lithium batteries.
FAQ
1. What is the main reason for using CAUTION and Overpack labels when shipping lithium battery packs?
You use these labels to ensure safe handling of batteries, prevent accidents, and comply with IATA regulations for air transport in sectors like Medical, robotics, and infrastructure.
2. Do I need to label every package if I ship multiple batteries in one overpack?
Yes. You must label each package containing batteries. The overpack also requires clear labeling to indicate the presence of batteries inside.
3. How can I get expert support for custom battery shipping compliance?
You can contact Large Power for tailored solutions and compliance guidance for batteries. Visit our OEM/ODM consultation page for more information.
