1 OCTOBER, 2025

How to transport lithium batteries safely – A freight forwarders guide

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You're just doing your job. But in today's fast-changing maritime world, where there are Lithium-ion batteries in almost every gadget and electric vehicle sales are booming, you can be directly exposed, personally blamed if the batteries are mis-declared, poorly packed, or damaged in transit. In this article we take a look at how to transport lithium batteries safely and what you can do, as a freight forwarder, to protect yourself and your clients.

Container shipping drives global trade, but with lithium batteries in more cargo, freight forwarders must know how to transport lithium batteries safely.

WHY IT’S IMPORTANT TO KNOW HOW TO TRANSPORT LITHIUM BATTERIES SAFELY

The world's shipping losses have plummeted by 50% in the last ten years, making shipping safer than ever. But there's a cloud on the horizon, with unusual numbers of ships catching fire when carrying Lithium-ion batteries, either as cargo in their own right, destined for electric bikes, mobile phones and so on, or actually inside EVs.

EXAMPLES OF LI-ION BATTERY FIRES ON BOARD SHIPS

In February 2022 the Pure Car and Truck Carrier (PCTC) MV Felicity Ace caught fire in the Atlantic Ocean, near the Azores. It was carrying 4,000 vehicles from Germany to the USA, many of them expensive EVs. It took more than a week to out out the blaze and she sank while being towed, a total insurance loss. The MV Fremantle Highway sank in July 2023, this time in the North Sea off mainland Europe. One crew member died, several were injured, and the fire burned for days.

In December the same year the MV Istra Ace caught fire in the North Atlantic, diverting to the Azores once the fire was put out. The MV Genius Star XI and the MV Kaimana Hila followed. From 2012 to 2021 fires caused 120 out of 892 reported losses at sea and between January 1 2017 and December 31 2021 fire cost the sector a total €9.2bn (≈RM47.8bn)

Cargo ship fire at sea linked to lithium-ion batteries – highlighting the urgent need for safe lithium battery transport in maritime shipping.

WHAT SHIPPERS AND INSURANCE COMPANIES ARE DOING ABOUT IT

Allianz Global Corporate & Specialty (AGCS) has come up with a list of recommendations to make transporting these batteries and the products they're fitted inside safer.

• Specific training for all the people involved
• Better pre-sail stability checks
• Accurate cargo information
• Improved cargo loading and securing procedures
• Flexible routes for vulnerable ro-ro and car carrier routes to avoid dangerous conditions
• Regular checks for battery damage, overcharging, short circuiting and overheating
• Improved fire detection and firefighting training on board
• Always taking note of the manufacturer’s recommendations
• Reviewing safety data to identify the latest preventive action
• Check all EVs display the battery type on their windshields
• Label all EVs with low ground clearance
• Check EV battery systems are undamaged
• Make sure EVs can't charge while at sea
• Organise watchkeeping and fire checking round the clock
• Fit thermal scanners, gas detectors, heat detectors, smoke detectors, and CCTV
• An Emergency Response Plan to tackle damaged or overheating, with special training for key employees
• A Hazard Control Plan to manage receiving, storage, dispatch and supervision of packaged batteries
• Create pre-emergency plans with local fire departments and on-site fire brigades as appropriate
• Make sure the batteries are stacked in designated areas, to safe heights.
• Keep at least 3m structural or spatial separation from other combustible materials when there isn’t automatic fire extinguishing equipment nearby.
• Never use rack storage for Li-ion batteries unless there's a sprinkler system plus solid vertical and horizontal metal barriers between the storage bays
• Remove all damaged or defective Li-ion batteries immediately
• Install gas detection for CO2 concentration, shock/impact sensors and vibration sensors for all large-format batteries
  

That's what your shipper can do for you. So what can you do as a freight forwarder?

A FREIGHT FORWARDER'S RESPONSIBILITY

If you're responsible for packing the goods, follow the latest and most comprehensive guidelines for packing lithium-ion batteries, or make sure the packaging company you hire has the right expertise.

Make sure your paperwork is 100% correct, accurately describing and documenting the cargo. And choose a reputable carrier, an experienced shipper who knows exactly how to manage the risks. You'll probably want to check their processes and procedures for yourself, or ask a fellow freight forwarder with experience in transporting Li-Ion batteries to make a recommendation.

Automated lithium-ion battery production line with strict quality control – ensuring safe lithium battery transport and reduced shipping risks.

Make sure you have enough good quality freight forwarders liability insurance in case something goes wrong. It usually covers physical damage or loss of goods during transit, Customs Liabilities against unexpected costs, fines, and delays because of mistakes in the paperwork, and legal expenses and claims from third parties for bodily injury or damaged property. It covers penalties for regulatory breaches enforced by the port authorities at either end, as well as unclaimed or abandoned cargo losses. Problems from essential operational activities like storage and distribution are covered, as are unforeseen accidents and hazards like fires and explosions. and other unforeseen events. Last but not least, it includes Employee and Personal Injury Support to cover claims from workplace injuries.

It's also important to buy the right amount and type of marine cargo insurance to cover the goods in transit, financial loss from damage or loss, and specialist protection like General Average, which lets cargo owners share responsibility.

Can we help you manage the risks of Li-ion battery transportation?

Now you understand more about how to transport lithium batteries safely. But you might appreciate some expert support. Because we understand your operational challenges, we can help you manage risk, and we're always happy to talk things through.

Please feel free to contact us.