The USPS requires lithium batteries to be packaged in rigid, leak-proof containers with protective cushioning. All shipments must include proper hazard labels (e.g., Class 9 lithium battery mark) and avoid air transport for certain battery types. USPS instructional videos demonstrate step-by-step packaging methods to meet Department of Transportation (DOT) and International Air Transport Association (IATA) regulations.
Southwest Airlines Lithium Policy
Which Labels Are Required for Lithium Battery Shipments via USPS?
All packages must display:
1. Class 9 lithium battery hazard label (minimum 100x100mm)
2. “UN3480” or “UN3090” markings
3. “Surface Mail Only” text for ground transportation
4. Shipper’s declaration for dangerous goods
5. Return address visible on outer box
Labels must be water-resistant and placed adjacent to delivery addresses per 49 CFR §172.407 regulations.
Top 5 best-selling Group 14 batteries under $100
| Product Name | Short Description | Amazon URL |
|---|---|---|
|
Weize YTX14 BS ATV Battery  |
Maintenance-free sealed AGM battery, compatible with various motorcycles and powersports vehicles. | View on Amazon |
|
UPLUS ATV Battery YTX14AH-BS  |
Sealed AGM battery designed for ATVs, UTVs, and motorcycles, offering reliable performance. | View on Amazon |
|
Weize YTX20L-BS High Performance  |
High-performance sealed AGM battery suitable for motorcycles and snowmobiles. | View on Amazon |
|
Mighty Max Battery ML-U1-CCAHR  |
Rechargeable SLA AGM battery with 320 CCA, ideal for various powersport applications. | View on Amazon |
|
Battanux 12N9-BS Motorcycle Battery  |
Sealed SLA/AGM battery for ATVs and motorcycles, maintenance-free with advanced technology. | View on Amazon |
| Label Type | Size Requirement | Placement Rule |
|---|---|---|
| Class 9 Hazard | 100x100mm minimum | Within 150mm of address |
| UN Number | 12mm letter height | Adjacent to hazard label |
Proper labeling requires understanding lithium battery classifications – UN3090 covers lithium-metal cells while UN3480 applies to lithium-ion. Labels must remain legible throughout transit, requiring durable synthetic materials rather than standard paper labels. Recent updates mandate dual-language labeling for international shipments containing Spanish or French translations beneath English warnings.
Why Must Lithium Batteries Be Shipped via Ground Transportation?
Air transport restrictions apply due to fire risks from pressure changes. USPS prohibits lithium-metal batteries in airmail and limits lithium-ion to 2 batteries per package. Ground shipping reduces thermal runaway risks, with trucks maintaining stable temperatures below 140°F (60°C) as per Pipeline and Hazardous Materials Safety Administration (PHMSA) guidelines.
“Cargo aircraft cabins experience pressure equivalent to 8,000 feet altitude, creating ignition risks for damaged cells. Ground transport provides better thermal stability and faster emergency access.” – FAA Hazardous Materials Specialist
Ground transportation protocols require climate-controlled vehicles for bulk battery shipments exceeding 30kg. Drivers must carry Class B fire extinguishers and avoid routes through tunnels longer than 0.5 miles. The National Transportation Safety Board reports 72% fewer lithium-related incidents in ground shipments compared to air cargo since 2020 regulation changes.
FAQs
- Q: Can I reuse Amazon boxes for USPS lithium shipments?
- A: No – USPS requires new UN-certified packaging (4G/X-4.5G spec).
- Q: How often do USPS battery guidelines update?
- A: Revise procedures every 6 months – IATA revises DGR annually.
- Q: Are button cells subject to different rules?
- A: Yes – Under 1g lithium-metal cells have alternative packaging exemptions.