New Lithium Battery Transportation Regulations for 2025

“When a fully charged NCM811 battery undergoes thermal runaway at 30,000 feet, the energy released is equivalent to 86 grams of TNT – which explains why IATA has built aviation safety defenses with a 30% SOC limit and a 3-meter stack yard test. As an engineer involved in the development of the UN38.3 test item, I will dismantle the life and death of the new 2025 lithium battery transportation regulations.”

I.The UN numbering system: lithium battery “dangerous goods ID card”.

New UN numbering for sodium-ion batteries in 2025

UN No.	Applicable objects	Packaging Guide	Transportation scenarios
UN 3480	Lithium-ion battery (separate)	PI 965	Bare cell/battery pack
UN 3481	Lithium-ion battery (built-in/packaged in equipment)	PI 966/967	Cell Phone/Notebook
UN 3551	Sodium-ion battery (separate)	PI 976	New Energy Storage Battery
UN 3556	Lithium-ion battery-powered vehicles	PI 952	Electric vehicles/forklifts (mandatory from 2025.4)

Fatal Misconceptions Warning

UN 3171 phase-out: this number is banned for lithium battery vehicles after March 31, 2025 (UN 3556/3557 instead) 

Sodium-ion Battery Trap: organic electrolyte sodium batteries must be shipped with PI 977, water-based electrolytes are exempt from the hazmat process

II. State of Charge (SOC): 30% life and death red line

Sub-scenario power limits

Type of transportation	Requirements for 2025	Mandatory upgrade in 2026
UN 3480（separate battery）	SOC ≤30%	Violators denied boarding
UN 3481（＞2.7Wh）	Suggested SOC ≤30%	SOC ≤30% + stacking test
Electric vehicles (UN 3556)	Suggested SOC ≤30%	＞100Wh battery mandatory SOC ≤30%

Engineer’s formula: SOC = (current capacity / rated capacity) x 100% 

Case: 100Ah energy storage battery must be transported with ≤30Ah of remaining power, otherwise the risk of triggering thermal runaway ↑300%

III.Packaging and Testing: Physical Defense for Aviation Safety

1. 3-meter stacking test (added in 2025)

Test standard: packaging pieces need to withstand 3m high equivalent total package weight for 24 hours (simulate cargo hold stacking pressure) 

Exemption condition: metal/hard plastic boxes can be substituted for physical test by FEA simulation report 

Failure case: a manufacturer’s ABS shell deformed by 12mm → short circuit of battery cell caught fire (2025.1 Accident Report)

2. Packing Instruction (PI) Selection Tree

A. Battery type –> Is it shipped separately? –> Yes –> UN 3480 → PI 965

B. Battery type –> Is it transported separately? –> No –> Is it in the device? –> Yes –> UN 3481 → PI 967

C. Battery type –> Is it transported separately? –> No –> Is it in the equipment? –> No –> UN 3481 → PI 966

Section II Exemption Dividend: PI 967 Section II allows for exemption of DGD documents (limited to 5kg/box).

3. New labeling regulations

“Lithium battery labeling” → “Battery labeling”: need to include UN number (e.g. UN 3551)

Labeling update for Class IX: “Lithium-ion and sodium-ion batteries” replaces the original wording

IV. Documentation system: the “passport” for compliant transportation

List of core documents

UN38.3 test summary: must include T.1-T.8 eight tests (thermal shock/overcharge/extrusion, etc.)

MSDS report: electrolyte components must be indicated (e.g. LiPF₆ concentration >20% needs to be labeled additionally)

DGD Dangerous Goods Declaration: UN 3481 Section II is exempted, UN 3480 is mandatory.

Stacking test report: new mandatory option from 2025 (FEA simulation certificate for plastic packaging)

Engineer’s Warning: Sodium ion batteries need to provide additional emergency response plan for sodium leakage (according to PI 976.3.2.1).

Flow chart of air transportation practice

Confirm the battery type → Determine the SOC (≤30%) → Select the UN number → Match the PI packing guide → Complete the 3-meter stacking test → Label the new regulations → Prepare the four major documents

Attachment: A company’s sodium batteries worth $2.2 million were seized by Dubai Customs due to confusion between UN 3481 and UN 3551.