USPS Packaging Instruction 9D

Lithium Metal and Lithium-ion Cells and Batteries — Domestic

Lithium metal (nonrechargeable) cells and batteries and lithium-ion (rechargeable) cells and batteries are mailable in limited quantities domestically via air or surface transportation when they are installed in or packed with the equipment they are intended to operate. Unless otherwise excepted, lithium metal and lithium-ion batteries (without equipment) are mailable in limited quantities domestically via surface transportation only.

Proper Shipping Name

• Lithium Metal Battery.
• Lithium-ion Battery.

ID Number

• Lithium-ion Battery, UN3480.
• Lithium Metal Battery, UN3090.
• Lithium-ion Battery contained in equipment, UN3481.
• Lithium-ion Battery packed with equipment, UN3481.
• Lithium Metal Battery contained in equipment, UN3091.
• Lithium Metal Battery packed with equipment, UN 3091.

Mailability

• Lithium metal and lithium-ion cells and batteries installed in or packed with equipment are mailable via air or surface transportation.
• Lithium-ion (or lithium polymer) batteries may be mailed, in limited quantities, via air transportation when both shipped from, and intended for delivery to, the state of Alaska under 349.222.
• Except as provided above, individual lithium metal (or lithium alloy) and lithium-ion (or lithium polymer) batteries (without equipment) are mailable in limited quantities via surface transportation only, provided the batteries are in the originally sealed packaging, and packaged and marked as described in 349.221 and 349.222, as applicable.

Required Packaging

Lithium Metal and Lithium-ion Batteries

• Packaging must meet all applicable requirements specified in 49 CFR 173.185. Except for mailpieces containing button cell batteries properly installed in the equipment they are intended to operate, mailpieces containing mailable lithium metal or lithium-ion batteries must be rigid, sealed, and of adequate size, so the lithium battery mark can be affixed to the address side without the mark being folded.
• Packaging must be strong enough to prevent crushing of the package or exposure of the contents during normal handling in the mail.
• The use of padded and poly bags as outer packaging is permitted only when the mailpieces contain button cell batteries meeting the classification criteria in 349.11d, the batteries are properly installed in the equipment they are intended to operate, and the batteries are afforded adequate protection by that equipment.
• All outer packages must have a complete delivery and return address.

Markings

• Lithium metal batteries properly installed in the equipment they are intended to operate:
• Except for mailpieces containing button cell batteries installed in equipment (including circuit boards), or no more than 4 lithium metal cells or 2 lithium metal batteries installed in the equipment they operate, mailpieces containing lithium metal batteries must bear a DOT-approved lithium battery mark, as specified in 49 CFR 173.185(c)(3)(i) and Exhibit 325.2a, applied to the address side of the mailpiece.
• The mark must indicate UN3091 for lithium metal cells or batteries installed in equipment.
• Where a package contains lithium cells or batteries assigned to different UN numbers, all applicable UN numbers must be indicated.
• The mark must also include a telephone number for those who need to obtain additional information.

Note: DOT-approved lithium battery markings must be applied to all mailpieces when there are more than two mailpieces in a single consignment as defined in 349.12b.

• Lithium metal batteries packed with the equipment they are intended to operate:
• Mailpieces must bear a DOT-approved lithium battery mark, as specified in 49 CFR 173.185(c)(3)(i) and Exhibit 325.2a, applied to the address side of the mailpiece.
• The mark must indicate UN3091 for lithium metal cells or batteries packed with equipment.
• The mark must also include a telephone number for those who need to obtain additional information.
• Lithium metal batteries not packed with or installed in equipment (individual batteries):
• Mailpieces must bear a DOT-approved lithium battery mark, as specified in 49 CFR 173.185(c)(3)(i) and Exhibit 325.2a, applied to the address side of the mailpiece.
• The mark must indicate UN3090 for lithium metal cells or batteries.
• The mark must also include a telephone number for those who need to obtain additional information.
• Mailpieces must also include the text “Surface Mail Only, Primary Lithium Batteries — Forbidden for Transportation Aboard Passenger Aircraft” or “Surface Mail Only, Lithium Metal Batteries — Forbidden for Transportation Aboard Passenger Aircraft.”
• Lithium-ion batteries properly installed in the equipment they are intended to operate:
• Except for mailpieces containing button cell batteries installed in equipment (including circuit boards), or no more than 4 lithium-ion cells or 2 lithium-ion batteries installed in the equipment they operate, mailpieces containing lithium-ion batteries must bear a DOT-approved lithium battery mark, as specified in 49 CFR 173.185(c)(3)(i) and Exhibit 325.2a, applied to the address side of the mailpiece.
• The mark must indicate UN3481 for lithium-ion cells or batteries installed in equipment.
• The mark must also include a telephone number for those who need to obtain additional information.

Note: DOT-approved lithium battery markings must be applied to all mailpieces when there are more than two mailpieces in a single consignment as defined in 349.12b.

• Lithium-ion batteries packed with the equipment they are intended to operate:
• Mailpieces must bear a DOT-approved lithium battery mark, as specified in 49 CFR 173.185(c)(3)(i) and Exhibit 325.2a, applied to the address side of the mailpiece.
• The mark must indicate UN3481 for lithium-ion cells or batteries packed with equipment.
• Where a package contains lithium cells or batteries assigned to different UN numbers, all applicable UN numbers must be indicated.
• The mark must also include a telephone number for those who need to obtain additional information.
• Lithium-ion batteries not packed with or installed in equipment (individual batteries):
• Mailpieces must bear a DOT-approved lithium battery mark, as specified in 49 CFR 173.185(c)(3)(i) and Exhibit 325.2a, applied to the address side of the mailpiece.
• The mark must indicate UN3480 for lithium-ion cells or batteries.
• The mark must also include a telephone number for those who need to obtain additional information.
• Mailpieces must also include the text “Surface Mail Only, Secondary Lithium Batteries — Forbidden for Transportation Aboard Passenger Aircraft” or “Surface Mail Only, Lithium-ion Batteries — Forbidden for Transportation Aboard Passenger Aircraft.”

Quantities

Domestic — Lithium Metal Cells and Batteries:

Installed in or packed with the equipment they are intended to operate:

• Each cell must contain no more than 1.0 gram of lithium content.
• Each battery must contain no more than 2.0 grams aggregate lithium content.
• The shipment cannot contain more batteries than the number needed to operate the device.
• Each mailpiece must contain no more than 8 cells or 2 batteries.

Individual batteries mailed without equipment:

• Each cell must contain no more than 1.0 gram of lithium content.
• Each battery must contain no more than 2.0 grams aggregate lithium content.
• The mailpiece must not exceed 5 pounds.

Domestic — Lithium-ion Cells and Batteries:

Installed in or packed with the equipment they are intended to operate:

• The total watt-hour rating for each cell must not exceed 20 Wh.
• The total watt-hour rating for each battery must not exceed 100 Wh.
• Each mailpiece must contain no more than 8 cells or 2 batteries.

Individual batteries mailed without equipment:

• The total watt-hour rating for each cell must not exceed 20 Wh.
• The total watt-hour rating for each battery must not exceed 100 Wh.
• The mailpiece must not exceed 5 pounds.

Domestic — Small Lithium Metal or Lithium-ion Batteries

Very small, consumer-type batteries, installed in equipment, or packed with equipment:

• Each lithium metal or lithium alloy cell or battery must contain no more than 0.3 gram of lithium content.
• Each lithium-ion or lithium polymer cell or battery must not exceed a watt-hour rating of 2.7 Wh.
• No limit on the number of cells/batteries.
• Each mailpiece must not exceed 2.5 kilograms (5.5 pounds) total weight.

Domestic Lithium Battery Mailability Exhibit

 

	Surface Transportation	Air Transportation	Mailpiece Limitations1
Lithium Metal or Lithium Alloy Batteries 2, 3 Small, non-rechargeable, consumer-type batteries
Contained in (properly installed in equipment)	Mailable	Mailable	8 cells or 2 batteries 11lbs.
Packed with equipment, but not installed in the equipment	Mailable	Mailable	8 cells or 2 batteries 11lbs.
Without the equipment they operate (individual batteries in originally sealed packaging)	Mailable	Prohibited	5 lbs.
Lithium-ion or Lithium Polymer Batteries 4, 5 Small, rechargeable, consumer-type batteries
Contained in (properly installed in equipment)	Mailable	Mailable	8 cells or 2 batteries
Packed with equipment, but not installed in the equipment	Mailable	Mailable	8 cells or 2 batteries
Without the equipment they operate (individual batteries in originally sealed packaging)	Mailable	Prohibited	5 lbs.
Without the equipment they operate (individual batteries in originally sealed packaging) (Intra-Alaska only)	*	Mailable	8 cells or 2 batteries
Very Small Lithium Metal or Lithium-ion Batteries 6, 7 Exception for very small consumer-type batteries in USPS air transportation
Contained in (properly installed in equipment)	Mailable	Mailable	No limit on cells/batteries 5.5 lbs.
Packed with equipment, but not installed in the equipment	Mailable	Mailable	No limit on cells/batteries 5.5 lbs.
Damaged/Recalled Batteries	Prohibited, unless approved by the manager, Product Classification.

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