Battery & Hazardous Item Rules for Mail and Couriers: A Global Guide
Shipping batteries or “hazmat” items isn’t just about boxes and labels—it’s about safety, compliance, and avoiding costly delays. I’ve learned that the clearest path is to follow the global rulebook and double-check local variations before I ship. This guide—written for shoppers and small businesses worldwide, including customers who use Global Shopaholics—breaks down what counts as hazardous, how battery rules work, and the steps to get compliant shipments moving with fewer surprises.
What counts as a “hazardous item”?
In transport, a hazardous item (dangerous goods/hazmat) is any substance that could pose an unreasonable risk to health, safety, or property while in transit. That includes obvious risks (explosives, flammable liquids) and less-obvious consumer items (aerosols, paints, strong magnets, some cosmetics, and many batteries). Proper packaging, labeling, documentation, and handling are what make these shipments safe and legal.
The nine hazard classes you’ll see on labels
Regulators group hazardous materials into nine classes, each with standard diamond-shaped labels used worldwide. Knowing the class helps you select the right packaging and paperwork:
Class 1: Explosives
Class 2: Gases
Class 3: Flammable liquids
Class 4: Flammable solids (4.1), spontaneously combustible (4.2), dangerous when wet (4.3)
Class 5: Oxidizers (5.1) and organic peroxides (5.2)
Class 6: Toxic (6.1) and infectious substances (6.2)
Class 7: Radioactive
Class 8: Corrosive
Class 9: Miscellaneous (includes many batteries and magnetized material)
Who makes the rules (and how they fit together)?
UN Model Regulations: The United Nations publishes a framework (“Orange Book”) that defines how dangerous goods are classified, labeled, and packaged. Countries and carriers align their own rules to this model.
ICAO & IATA for air: For air transport, the ICAO Technical Instructions and the IATA Dangerous Goods Regulations (DGR) translate UN rules into airline-ready procedures and packing instructions. Shippers, couriers, and postal operators follow these for any air segment.
UPU for international mail: Postal shipments must also meet Universal Postal Union (UPU) prohibitions and each destination country’s postal list of items that are not admitted. Some countries prohibit entire categories of dangerous goods in the mail.
Batteries 101: the essentials shippers must know
Lithium batteries dominate today’s rules because they can overheat and enter thermal runaway if damaged or short-circuited. That’s why regulations hinge on the battery type and energy (Watt-hours for lithium-ion; lithium content in grams for lithium-metal). Spares, batteries in equipment, and baggage/travel scenarios each have different limits and approvals—particularly in air transport.
Lithium battery types and common thresholds (air context)
Lithium-ion (rechargeable): Governed by Watt-hours (Wh).
Lithium-metal (non-rechargeable): Governed by grams of lithium content.
Typical air rules distinguish between batteries installed in equipment vs. spares, with stricter limits for spares and large capacities (e.g., around the 100–160 Wh range for certain approvals). Exact allowances depend on the operator and national variations, so always verify before shipping.
Important: All lithium cells and batteries offered for transport must have passed UN 38.3 tests (design safety tests such as altitude simulation, vibration, shock, etc.). Keep (or be able to obtain) the UN 38.3 Test Summary from the manufacturer or supplier.
Damaged, defective, or recalled batteries
These are forbidden in air transport because they present elevated risk and have caused incidents. If you suspect damage (swelling, leakage, overheating), do not ship by air—and check whether any ground option is lawful in your route.
Hazardous items often restricted or prohibited in mail
While private couriers may accept some dangerous goods prepared under strict conditions, postal networks are far more restrictive. Many postal operators do not accept lithium batteries at all—especially spares—and broadly prohibit dangerous goods, along with other non-admitted items (e.g., certain chemicals, flammable aerosols, or corrosives). Always check the destination country’s current “items not admitted” list.
Why air rules keep changing
Aviation regulators update battery policies as risks and technology evolve. For example, the ICAO Council prohibited bulk lithium-ion battery cargo on passenger aircraft in 2016, and many authorities have refined lithium battery carriage and charging restrictions since. In 2025, some countries and airlines tightened on-board device and power-bank rules due to incident trends—reminding shippers that local variations matter.
Packaging, labeling, and paperwork: getting it right
Plan your shipment like an auditor would. Before you hand a parcel to any copyright, confirm these:
Classification: Identify the correct UN number and proper shipping name (e.g., UN3480/UN3481 or UN3090/UN3091 for lithium batteries).
UN 38.3 Test Summary: Obtain it from your supplier; you may be asked to produce it.
State of Charge (SoC) and configuration: Some lithium-ion cargo must be shipped at limited SoC; rules differ by scenario and packing instruction. iata.org
Packaging: Use tested inner protection to prevent short circuits; isolate terminals; prevent movement.
Marks and labels: Apply the lithium battery mark when required; use the correct hazard labels and “Cargo Aircraft Only” label if applicable.
Documentation: Dangerous Goods Declaration (when required), accurate description, and emergency contact details. For mail, also confirm the UPU/destination prohibitions before you pack.
Mail vs. courier: what’s the practical difference?
International mail (postal operators) follows the UPU framework and is typically stricter: many posts simply do not accept lithium batteries or other dangerous goods, full stop. Even where allowed, the list of exceptions is narrow and can change without much notice.
Couriers/forwarders can often transport certain dangerous goods by air cargo if the shipment meets IATA DGR packing instructions and documentation. That said, couriers still apply operator variations and destination-country rules; never assume acceptance without pre-clearance.
A five-step self-assessment before you ship
Identify the item: Is it a battery, aerosol, chemical, magnet, or something with flammable propellant? If yes, treat it as potential hazmat.
Check the rulebook: Look up ICAO/IATA rules for air segments and any UPU and destination-country postal prohibitions for mail.
Verify battery data (if applicable): Wh rating or lithium content, whether it’s installed in equipment or shipped as a spare, and whether any SoC limits or operator approval apply.
Gather proof: Keep the UN 38.3 Test Summary, SDS (if provided), and accurate product specs handy for copyright review.
Package and label: Prevent short circuits, cushion against impact, and apply the correct marks/labels. If your shipment is mail, re-check the items not admitted list just before posting.
FAQs (quick hits)
Can I mail a power bank internationally? Often no via postal channels; rules vary by country, and many posts prohibit standalone lithium batteries. Couriers may accept under IATA rules if fully compliant.
What if my battery looks swollen or damaged? Do not ship by air; damaged/defective/recalled lithium batteries are forbidden.
Why do limits differ between “in equipment” vs. “spares”? Spares present higher short-circuit risk; that’s why air rules set stricter controls and approvals for loose batteries. iata.org
Conclusion
Shipping batteries and other hazardous items safely is all about identification, documentation, and discipline. Start with the global playbook (UN/ICAO/IATA), confirm postal prohibitions and operator variations, and package to a standard that would satisfy an auditor. When in doubt, pause and verify—because the quickest shipment is the one that’s compliant the first time.