​Best Practices For Handling EV Batteries During Shipping

The electric and hybrid vehicle revolution has transformed the way that consumers purchase and operate cars, and has also posed significant challenges for automotive businesses.

Among the most pressing of these challenges is the task of shipping electric vehicle (EV) batteries safely and efficiently. These high value but potentially hazardous components require specialist handling and storage procedures that go beyond those required for many traditional automotive parts. In this article, we look at the main challenges facing EV battery shipping and best practices you can adopt to mitigate risk.

What’s So Challenging About EV Battery Shipping?

Accustomed as we are to using batteries for a wide range of consumer devices and appliances, it’s easy to overlook the dangers of shipping powerful lithium-ion battery packs and individual cells by ship, across long distances. EV batteries present a range of unique logistical challenges that require careful consideration and planning, such as:

1. Fire and safety risk: Battery damage during shipping (e.g. from vibrations or overheating) can result in thermal runaway, causing on-board chemical fires or toxic gas release. Once a fire starts on board ship, it can be very difficult to contain, especially if the blaze spreads to adjoining vehicles on a Ro-Ro ferry. Additionally, the substantial weight of many electric vehicle batteries, often as much as 400 to 600 kg each, creates a handling challenge that increases the risk of injury to personnel, and equipment damage. Ambient and environmental factors such as temperature extremes and choppy seas during transport can further compromise battery integrity.
2. Regulatory compliance: EV batteries fall under strict international shipping regulations, largely due their proven danger as a fire hazard. Lithium-ion batteries are classified as dangerous goods under UN 3480 (batteries alone), and UN 3481 (for batteries packed with or contained in equipment). These classifications necessitate specific packaging strategies, documentation, and handling requirements, depending on the battery capacity, shipping method, and destination.
3. Cost management: As a result of these risks and regulations, standard shipping methods often prove inadequate for electric vehicle batteries, increasing freight charges and handling fees, and raising the overall cost of shipping, as well as leading to potential delays. Poor planning can also result in batteries arriving damaged or being impounded at port, leading to expensive warranty claims and customer dissatisfaction.

What Can Be Done To Mitigate These Challenges?

Invest in packaging and protection for your batteries

To avoid issues during transit, it’s worth investing in UN-specification packaging designed specifically for lithium-ion batteries or their components. This includes, for instance, impact-resistant outer containers, cushioning materials that prevent movement, and suitable insulation to maintain a stable temperature. Each battery should also be individually wrapped and secured to avoid contact with other batteries or conductive materials. It’s also important to ship your batteries at the appropriate charge level – typically between 30 to 50% state of charge – to minimise your fire risk whilst still maintaining cell stability during transport.

Goods certification

It’s important to obtain the appropriate dangerous goods certification for all employees handling EV batteries, while also confirming that your shipping documentation includes accurate battery specification, emergency response information, and UN numbers. Different shipping modalities (e.g. air, sea, train, road etc) have varying restrictions in different countries, so verify the requirements of your chosen transport method in advance to avoid delays. When shipping electric vehicles or batteries, we recommend working with a carrier experienced in dangerous goods transport who understands the EV battery-specific requirements, and who can provide the appropriate insurance coverage.

Containerised shipping

Containerised shipping is inherently safer for electric vehicle batteries than Ro-Ro, as the batteries are safely contained within sealed shipping containers, reducing the risk of a fire spreading across ship. However, if you are using container shipping for your vehicles, we recommend investing in a specialist racking system, such as our R-RAK or EL-RAK solution, to maximise the benefits. These systems offer several advantages for electric vehicle battery transport.

1. Enhanced protection: Your batteries remain securely positioned throughout the journey, minimising the vibration and impact damage that can occur with traditional shipping methods
2. Space utilisation: A containerised racking system maximises space utilisation within each container, allowing multiple batteries to be shipped safely within a single container – away from their vehicle if necessary – while maintaining proper separation and ventilation.
3. Minimised handling: Once loaded into a racking system, the batteries don’t need to be handled again until they reach their destination, reducing the risk of damage or accidents during transfer between transport modes.
4. Reusable infrastructure: Unlike disposable wooden crating and other racking systems, steel racking systems can be reused hundreds of times, reducing your long-term costs and environmental impact.

Find Out More

If you would like to find out more about containerised car transport and how to improve safety and efficiency while shipping EV batteries, please download a free copy of our Containerised Car Transport Guide today by clicking here.

​Image source: Canva