Transporting Lithium Batteries by Truck: A Comprehensive Guide for U.S. Motor Carriers
Learn the facts about transporting lithium-ion batteries by truck in the U.S., including whether hazmat placards are required, insurance requirements, packaging standards, and how Cogo Insurance supports long-haul truckers.
With the exponential rise in demand for electric vehicles, solar energy storage, and electronics, lithium-ion batteries have become one of the most transported energy storage devices on American highways. Yet, confusion persists among motor carriers regarding the exact federal requirements for hauling these batteries. Do you need hazmat placards? A CDL with hazmat endorsement? Specialized $5 million liability insurance?
In this definitive guide, Cogo Insurance breaks down the federal rules, safety standards, and best practices for long-haul truckers hauling lithium batteries—along with how we help our clients stay compliant and protected.
Are Lithium Batteries Considered Hazardous Materials?
Yes. Under the U.S. Department of Transportation’s Hazardous Materials Regulations (HMR; 49 CFR Parts 171-180), lithium cells and batteries are classified as Class 9 (Miscellaneous Hazardous Materials) due to the risk of fire or explosion if mishandled.
UN Numbers to Know:
- UN3480: Lithium-ion batteries
- UN3481: Lithium-ion batteries packed with or contained in equipment
- UN3090: Lithium metal batteries
- UN3091: Lithium metal batteries packed with or contained in equipment
However, the classification does not automatically mean placards or a hazmat CDL endorsement are required for domestic trucking.
Placards and Hazmat Endorsements: Not Required for Domestic Trucking
According to a formal PHMSA interpretation letter (Reference No. 22-0086, November 7, 2022):
“A driver is not required to have a hazmat endorsement on their CDL to transport lithium-ion batteries by highway in the United States. Section 172.504(f)(9) states that a Class 9 placard is not required for domestic transportation.”
This means that long-haul truckers moving lithium batteries across state lines in the U.S. do not need to display hazmat placards and do not require a hazmat endorsement, even if the batteries exceed 300 Wh. Source: PHMSA Interpretation Response No. 22-0086
If you like to read the law, here it is:
Ҥ 173.155 Exceptions for Class 9 (miscellaneous hazardous materials).
(a) General. Exceptions for hazardous materials shipments in the following paragraphs are permitted only if this section is referenced for the specific hazardous material in the § 172.101 table of this subchapter.
(b) Limited quantities of Class 9 materials. Limited quantities of miscellaneous hazardous materials in Packing Groups II and III are excepted from labeling requirements, unless the material is offered for transportation or transported by aircraft, and are excepted from the specification packaging requirements of this subchapter when packaged in combination packagings according to this paragraph. Unless otherwise specified in paragraph (c) of this section, packages of limited quantities intended for transportation by aircraft must conform to the applicable requirements (e.g., authorized materials, inner packaging quantity limits and closure securement) of § 173.27 of this part. A limited quantity package that conforms to the provisions of this section is not subject to the shipping paper requirements of subpart C of part 172 of this subchapter, unless the material meets the definition of a hazardous substance, hazardous waste, marine pollutant, or is offered for transportation and transported by aircraft or vessel, and is eligible for the exceptions provided in § 173.156 of this part. In addition, packages of limited quantities are not subject to subpart F (Placarding) of part 172 of this subchapter. Each package must conform to the packaging requirements of subpart B of this part and may not exceed 30 kg (66 pounds) gross weight. Except for transportation by aircraft, the following combination packagings are authorized:
(d) Reverse logistics. Except for Lithium batteries, hazardous materials meeting the definition of “reverse logistics” under § 171.8 of this subchapter and in compliance with paragraph (b) of this section may be offered for transport and transported in highway transportation in accordance with § 173.157.”
Insurance Requirements for Lithium Battery Transport
Despite their classification as Class 9 hazardous materials, lithium batteries do not fall under FMCSA’s higher hazmat insurance tier (which is $5 million). Instead, it’s a low-level hazmat, requiring $1 million in auto liability and cargo insurance. Most brokers and shippers still require:
- $1 million CSL (Combined Single Limit) Auto Liability
- Motor Truck Cargo (MTC) Insurance, typically up to $250K primary and $750K excess layer
There is no requirement for a $5 million hazmat policy unless other materials are involved.
Training Requirements
Per 49 CFR §172.704 and §177.816, while a hazmat endorsement is not needed, drivers transporting Class 9 materials are still considered “hazmat employees” and must receive:
- General Awareness Training
- Function-Specific Training
- Safety Training
- Security Awareness Training
This training must be refreshed every three years and documented by the carrier. Cogo Insurance partners can access free training templates and DOT-compliant certification support.
Packaging and Fire Safety Requirements
For fully regulated lithium-ion batteries (UN3480, >300Wh), the following packaging rules under §173.185 apply:
- Batteries must be protected from short circuits
- Batteries must be individually packed or separated with cushioning
- Packaging must pass a 1.2-meter drop test
Fire Safety: While not mandated in HMR, FMCSA recommends:
- Minimum of one 10-BC fire extinguisher
- Regular inspection of battery loads
Why Cogo Insurance Is the Right Partner
At Cogo, we understand lithium battery transport. Our tailored insurance programs ensure:
- $1M auto liability and can provide up to $5 Million in cargo
- Risk-specific underwriting for electronics, EV supply chains, solar battery units
- Access to DOT training resources
- Class 9 placards
- Special fire extinguishers
- Claims guidance if a lithium-related fire or loss occurs
Whether you haul clean energy tech, laptops, or EV batteries, Cogo helps you run safer, smarter, and fully compliant.
Conclusion
Truckers moving lithium batteries across America do not need hazmat placards or endorsements, but they do need to follow specific packaging and training requirements. With the right insurance, fire safety protocols, and DOT-compliant training, lithium battery transport can be both profitable and low-risk.
Cogo Insurance is here to help. Contact us today to get covered.
