Transporting Lithium-Ion Batteries in Your Van: What UK Tradespeople Need to Know

Every UK tradesperson carrying a set of cordless tools is also transporting lithium-ion batteries. Most do it without a second thought. A couple of spare 18V packs in the toolbox, maybe a larger 5Ah battery on charge in the cab. It is routine. But lithium-ion batteries are classified as Class 9 dangerous goods under UK and international transport regulations, and there are rules about how many you can carry, how they need to be stored, and what state of charge they should be in.

This is not about scaremongering. The rules exist because lithium-ion batteries can, in very specific circumstances, go into thermal runaway, a condition where a damaged or faulty cell heats up in a way that becomes self-sustaining. It is rare, but it is serious when it happens. The regulations are designed to reduce the probability and severity of incidents during transport.

Here is what the rules actually mean for the average UK tradesperson.

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The classification: what are lithium-ion batteries under transport law?

Lithium-ion batteries fall under Class 9 miscellaneous dangerous goods in the ADR framework. ADR stands for the European Agreement Concerning the International Carriage of Dangerous Goods by Road. The UK maintained its own equivalent framework (CDG, the Carriage of Dangerous Goods regulations) following Brexit, and it closely mirrors ADR for road transport purposes.

The specific UN number for lithium-ion batteries transported alone, not contained in or packed with equipment, is UN 3480. When batteries are packed with equipment, or already installed in equipment, different UN numbers apply (UN 3481 and UN 3481 respectively). Power tool batteries in their raw pack form, separate from any tool, fall under UN 3480.

The Watt-hour rating of the battery determines which specific rules apply. A standard 18V 5Ah battery has a Watt-hour rating of 90Wh (volts multiplied by amp-hours). A 36V 5Ah pack is 180Wh.

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The thresholds: when do the rules kick in for a typical van?

This is where it gets practical. ADR includes a provision called the total quantity exemption, also referred to as the 1,000 point threshold. Each dangerous goods category is assigned a transport category and a multiplier. For lithium-ion batteries, the multiplier is 3. This means you divide the total Watt-hours of the batteries you are carrying by 3 to get your point score.

To stay under the 1,000 point exemption threshold with a multiplier of 3, you can carry up to 333Wh of loose lithium-ion batteries before the full ADR requirements apply. That is roughly three 18V 3Ah packs (54Wh each) or two 18V 5Ah packs (90Wh each).

However, batteries that are installed in equipment or packed with equipment are treated differently. Tools with batteries fitted, or batteries in the same packaging as the tool they came with, are generally subject to fewer restrictions at the quantities a typical tradesperson carries.

In practice, most UK tradespeople carry batteries in the UK under a combination of the limited quantities provisions and common exemptions that apply to private or professional users transporting tools as part of their trade. The critical factor is whether the batteries are loose, damaged, or in quantities that put you above the exemption thresholds.

Makita UK has published specific guidance on their battery transport requirements (MB_36), which covers how their batteries should be packaged and transported. It is worth reading alongside the generic regulations.

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The state of charge question

One of the most practically important requirements under ADR is the state of charge limit. For international air transport, the limit is 30% state of charge for lithium-ion batteries. For road transport under ADR, the situation is different: there is not a strict maximum state of charge for road transport in the way there is for air freight.

However, the principle of not transporting damaged or swollen batteries applies regardless of any specific state of charge rule. A battery that shows signs of physical damage, swelling of the cells (the pack becomes visibly distorted), unusual heat, or that has been involved in any kind of impact should not be transported until it has been assessed. Manufacturers including Makita publish specific guidance on what to do with a damaged battery.

The practical rule: transport batteries that are in good condition, avoid transporting fully charged batteries you do not need for the day (unnecessary risk for no operational benefit), and never transport a battery that you have any concern about.

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How to store batteries safely in a van

The physical storage setup matters. Lithium-ion batteries should be:

Protected from short-circuit. Terminal contact with metal objects (loose screws, fixings, other battery terminals) can cause a short circuit that generates enough heat to start a fire. Store batteries in their original cases, dedicated battery holders, or with terminal protectors fitted. Most manufacturers' battery packs have push-in contacts that are recessed, but the terminals on older or worn packs can be more exposed.

Protected from heat. A van parked in direct sun in summer can reach 70 degrees Celsius internally. Sustained high temperatures accelerate battery degradation and, in extreme cases, can contribute to cell failure. Store spare batteries in a cool part of the van or take them inside if leaving the vehicle for extended periods in hot weather.

Secured against movement. Batteries bouncing around in the back of a van risk physical impact damage. Tool cases or dedicated storage racking help here. A battery that has been dropped or suffered a significant impact should be inspected before use.

Separated from flammable materials. Lithium-ion fires burn very hot and are difficult to extinguish. Keeping batteries away from petrol, solvents, and similar materials is basic common sense.

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What if a battery goes wrong in transit?

A lithium-ion battery that starts to heat up, produce a smell, or begins to swell is showing early signs of thermal runaway. If this happens in a moving vehicle, the priority is to stop the vehicle safely, remove the battery from the vehicle if it is safe to do so, and keep distance. Do not put it in water. Lithium-ion fires are not extinguished by water and can react badly to it.

Leave the battery on a non-flammable surface well away from the vehicle and any other flammable material. Call the fire service if you have any concern about it.

Makita's own guidance recommends that if a battery becomes hot, damaged, or shows signs of leaking, it should be placed in a fireproof metal container or in a location away from flammable materials before being taken to a disposal point. Do not put it in a wheelie bin.

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Disposing of old lithium-ion batteries

Used and end-of-life power tool batteries should not go in household waste or trade waste skips. They are subject to the UK's WEEE regulations (Waste Electrical and Electronic Equipment). Most tool manufacturers, including Makita, Milwaukee, and Bosch, run take-back schemes at their service centres. Merchant trade counters often have battery collection points. Local authority recycling centres generally accept them.

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