AFMAN 24-204(I)/TM 38-250/NAVSUP PUB 505/MCO P4030.19H/ DLAI 4145.3
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11 DECEMBER 2001
- However, batteries may be packed with portable searchlights, battery parts, or hydrometers, if properly cushioned
and securely packed in a separate container.
A12.5.1. Packagings identified in this paragraph must meet PG II performance standards. The following
specification packagings are authorized for batteries packed without other materials:
A12.5.1.1. Wooden box (4C1, 4C2, 4D, 4F).
A12.5.1.2. Fiberboard box (4G).
A12.5.1.3. Plywood (1D) or fiber (1G) drum.
A12.5.1.4. Plastic drum (1H2), plastic jerrican (3H2), or solid plastic box (4H2).
A12.5.2. Pack non-spillable batteries in strong outer packagings. To consider a battery non-spillable, it must
withstand without leakage the vibration and pressure differential tests specified in 49 CFR 173.159(d). Batteries
meeting the additional requirement of Special Provision A67 are considered dry, and are not subject to any other
requirements of this manual.
A12.5.3. Package electrolyte, acid, or alkali corrosive battery fluid, packed with storage batteries wet or dry, in one
of the following packagings:
A12.5.3.1. Wooden box (4C1, 4C2, 4D, 4F) with inside glass receptacles not over 4.0 L (1 gallon) capacity each.
Maximum quantity per outside container is 8.0 L (2 gallons.) Cushion and separate the inside containers from
batteries by a strong solid wooden partition.
A12.5.3.2. Wooden box (4C1, 4C2, 4D, 4F) with inside plastic bottles not over 1 L (1 quart) capacity each. Pack no
more than 24 bottles, securely separated from storage batteries and filling kits in each package.
A12.5.3.3. Package dry storage batteries or battery charger devices in fiberboard boxes (4G) with inner receptacles
containing battery fluid. Complete package must conform to PG II requirements. Pack no more than 12 inner
receptacles in one outer box. Maximum authorized gross weight is 34 kg (75 pounds).
A12.5.4. The following nonspecification packagings are authorized for domestic only shipments of batteries
packed without other materials:
A12.5.4.1. One to three batteries of not over 11.3 kg (25 pounds) each, packed in an outside box. Gross weight
must not exceed 34 kg (75 pounds).
A12.5.4.2. A maximum of four batteries not over 7 kg (15 pounds) each may be packed in strong outside fiberboard
or wooden boxes. They must be cushioned and packed to prevent short circuits. Gross weight must not be over 30
kg (65 pounds).
A12.5.4.3. A maximum of five batteries not over 4.5 kg (10 pounds) each may be packed in an outside fiberboard
or wooden box. They must be securely cushioned and packed to prevent short circuits. Gross weight must not
exceed 30 kg (65 pounds).
A12.5.4.4. Single batteries not over 34 kg (75 pounds) each, packed in five-sided slipcovers or in completely closed
fiberboard boxes. Slipcovers and boxes must be of single or double-faced corrugated fiberboard of at least 91 kg
(200 pounds) test strength. The slipcover or the fiberboard box must fit snugly and provide an inside top clearance
of at least 1.3 cm (one-half inch) above battery terminals and filler caps with reinforcements in place. When
assembled for shipment, the bottom edges of the slipcover may extend to the base of the battery and must not expose
more than 25.4 mm (1 inch). The completed package (battery and box or slipcover) must be capable of
withstanding a top-to-bottom compression test without damage to the battery terminals, cell covers, or filler caps.
A12.5.4.5. Single batteries exceeding 34 kg (75 lbs) each may be packed in completely closed fiberboard boxes.
Boxes must be double-wall corrugated fiberboard of at least 181 kg (400 lbs) test, or solid fiberboard testing at least
181 kg (400 lbs). A box may have holes in its ends provided that the handholes will not materially weaken the box.
Sides and ends of the box must not be less than 1.3 cm (0.5 inch); and cushioning must be excelsior pads, corrugated
fiberboard, or other suitable cushioning material. Protect the bottom of the battery by a minimum of one excelsior
or double-wall corrugated fiberboard pad. Protect the top of the battery by a wood frame, corrugated trays or scored
sheets of corrugated fiberboard having minimum test of 91 kg (200 lbs), or other equally effective cushioning
material. Ensure the top protection bears evenly on connectors and/or edges of the battery cover to facilitate
stacking of batteries. No more than one battery may be placed in one box. The maximum authorized gross weight
is 91 kg (200 lbs).
A12.5.4.6. Large electric storage batteries protected against short circuit and firmly secured to skids or pallets
capable of withstanding the shocks normally incident to transportation. The height of the completed unit must not
be greater than 1.5 times the width of the skid or pallet. The unit must weigh not less than 136 kg (300 lbs) gross
and must not fail under a superimposed weight equal to two times the weight of the unit. If the weight of the unit is
greater than 907 kg (2,000 lbs), it must not fail with a superimposed weight of 1814 kg (4,000 lbs). Battery
