Lead Acid Battery Packaging – Last Revised 01/18/16 Page 1
Lead Acid Battery Packaging
Important Pallet and Packaging Specifications:
1. Maximum pallet sizes: 40" x 48" or 44" x 48"
2. Maximum layers per pallet: 3 – roughly 24 batteries/layer = 72 batteries for 3 layers.
3. Typical Pallet Weight (for 3 layers): Between 2800 and 3300 lbs – Pallets are not to
exceed 3300 lbs.
4. Only lead-acid batteries may be packaged: No mixing in other batteries or recyclables.
5. Pallet must be built with a minimum of 3 bottom boards
and durable enough to handle the weight of the batteries.
Instructions for Stacking Lead Acid Batteries on a Pallet
1. Select a sturdy pallet with no broken or missing boards.
Be sure there are no nails sticking out, which could
puncture the batteries or pose a safety hazard.
2. Place a layer of cardboard on the pallet to create a flat work surface and help prevent
batteries from sliding off of the pallet.
A pallet with a layer of cardboard
An example of a typical wood pallet
This pallet has 3 bottom boards
Lead acid batteries must have a layer
cardboard separating each level.
This includes a layer of cardboard on
the bottom and the top of the load.
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Lead Acid Battery Packaging
3. Make the first layer of batteries as level and as close
together as possible.
If some of the batteries are shorter, they should be
placed in the center of the layer.
Batteries that are relatively taller should be saved and
placed on the top layer (if stacking more than 1 layer).
Ensure no batteries are hanging over the edge of the
cardboard/pallet.
4. Place cardboard (multiple sheets if necessary) between each layer of batteries.
It is best to use the thick honeycomb cardboard (if available).
Examples of honeycomb cardboard
Alternatively, multiple layers of cardboard can also be used.
Examples of layers of typical cardboard
Enough layers of cardboard must be applied to achieve
the following:
o Prevent the possibility of short circuits; and
o Prevent the terminals from puncturing the underside
of the batteries in the layer above.
Note #1: Side terminal batteries must be stacked so the posts are facing away from each
other and not facing towards the outside of the pallet. Side terminals must never touch
(below displays overhead views of “Side Terminal Batteries”).
Single layer of batteries
2 layers of batteries with honeycomb
cardboard separating the two layers
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Lead Acid Battery Packaging
Note #2: Top posts must be positioned toward the outside of the
pallet so the layer above it leans toward the center. Make sure that
no batteries are overhanging the cardboard.
Note #3: Stud post batteries (such as Marine Batteries) should be on
the top layer. If this is not possible, you will need extra layers of
cardboard between the layers of batteries to prevent punctures. This
is also important when stacking three layers high.
5. A maximum of 3 layers of batteries may be placed on a pallet. When stacking is
complete, place cardboard on top of the final layer of batteries.
6. Any battery that has been damaged and has the potential to leak must first be placed in
a container capable of holding its contents.
Examples of damaged lead acid batteries
Damaged batteries that are not visibly leaking electrolyte should be put in
heavyweight polyethylene plastic bags (minimum: 6 mil), properly sealed with
plastic tie, and placed in the middle of the top layer.
Damaged batteries that have the potential to leak must be placed in a
container that is capable of holding its contents (i.e. will not leak fluid)
such as a DOT approved 5- gallon bucket.
Example: The top “stud post” battery has its terminals positioned
toward the outside of the pallet, and would need extra layers of
cardboard to prevent puncturing the next layer of batteries.
An example of a DOT approved 5-gallon container
3 layers of batteries with a
layer of cardboard on top.
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Lead Acid Battery Packaging
Instructions for Wrapping Pallet
All batteries should be secured to the pallet with stretch wrap. An 80 gauge (or stronger)
stretch wrap is recommended. Stretch wrap works best if it is pulled tight before stretching it
around the corners.
1. Start with the stretch wrap turned sideways to create
a “rope-effect”. Wrap around the top layer twice.*
2. Using the rope-effect, wrap the top layer twice* more,
each time crossing over the top to form an “X-pattern.”
This should pull the batteries towards the center,
preventing batteries from falling off of the pallet.
3. Holding the stretch wrap open, wrap around the bottom layer twice*, being sure to
catch the edges of the pallet.
4. After placing a layer of cardboard on top of the batteries, wrap
around the top layer at least twice* and tear-off the stretch wrap
at the last corner.
*Note: After wrapping twice (during each step) judge the load;
wrap as many times as necessary to stabilize the load.
5. To further secure the load,
band the material to the pallet.
*Note: After wrapping twice (during each step) judge the
load; wrap as many times as necessary to stabilize the load.
Creating a “rope-effect” with stretch wrap
Holding the stretch wrap open
3 layers of batteries wrapped up
Fully wrapped pallet of batteries
A wrapped and banded pallet
of lead acid batteries (3 levels)
6. Finally, ensure the pallet is properly labeled. At
minimum, the pallet should include a #8 Corrosive
and a Universal Waste Label. Check with your
transporter to see if any additional labeling is
required.
Ex: #8 Corrosive Label
Ex: Universal Waste Label