How to ship an IMA battery - My solution (Pics)

[jeff652]

This is my single use solution on how to ship IMA batteries. I purchase two 6.0 cu. ft. packing boxes from home depot (24x24x24 inch size), two cans of large gap filler insulating spray foam, about six feet of bubble wrap, and a large 3 mil construction trash bag. Total packaging costs are just under $20.

The second box is sliced into 24"x24" squares (two flaps combine to make one square) and are layered on the bottom of the main box to provide bottom support and cushion the battery. The top flaps of the main box are sliced off to add additional layers and new flaps are cut out of the top 12" of the box. Bubble wrap is added as insurance cushioning around the sensitive end of the battery. The spray foam is concentrated around the battery bolt down 'arms' and when cured will tightly hold the battery within the box. A "Fragile! Do Not Drop! Do Not Tip!" label on each side and it is ready to go!



I will update this tomorrow with the shipping weight to help other forum members get an idea on what is involved in safely shipping IMA batteries.

[jeff652]

Here is the morning after photo . The foam has expanded, cured, and locked the battery in place. The shipping weight is 76 lbs. A bit of tape to close it up and this battery is ready to go!

[Rush]

Very Nice! the expanding foam is a great idea and it conforms to whatever it is in contact with so the Garbage bag is also a great idea!

[Hybrid-Battery-Repair]

Jeff,

From our experience, this doesn't work well. If the sides of the carton are rigid (wood crate) then this works well for many trips. Otherwise, the weight of the battery wil bow the side slightly and create a gap. The battery will then pulverize the material at the gap and will start flopping around.

Once the battery can move, you get a crushed junction board and broken ears. We had one box come back from the west coast in the shape of a beach ball. It was round!

We spent 4 years testing different shipping methods, so we tried just about everything.

We found that the best way was to use a large amount of bubble wrap tightly wrapped around the battery to cushion it. we also taped a 2x3 to the non-junction board end to protect the ears. If the package is dropped on that corner, the wood takes the impact. you can use a 24x24x12 box for an Insight.

Also, use FedEx ground, not UPS. They are much more gentle.

Ron

Originally Posted by jeff652

This is my single use solution on how to ship IMA batteries. I purchase two 6.0 cu. ft. packing boxes from home depot (24x24x24 inch size), two cans of large gap filler insulating spray foam, about six feet of bubble wrap, and a large 3 mil construction trash bag. Total packaging costs are just under $20.

The second box is sliced into 24"x24" squares (two flaps combine to make one square) and are layered on the bottom of the main box to provide bottom support and cushion the battery. The top flaps of the main box are sliced off to add additional layers and new flaps are cut out of the top 12" of the box. Bubble wrap is added as insurance cushioning around the sensitive end of the battery. The spray foam is concentrated around the battery bolt down 'arms' and when cured will tightly hold the battery within the box. A "Fragile! Do Not Drop! Do Not Tip!" label on each side and it is ready to go!



I will update this tomorrow with the shipping weight to help other forum members get an idea on what is involved in safely shipping IMA batteries.

[zzz503]

I know this is an old thread, but I'm hoping to revive it for clarification and advice.

Ron seems to be saying that bubble wrap (i'm assuming the large bubble wrap like shown in the OP's photo) is better than expanding foam? Correct?

I'm not sure exactly what a 2x3 piece of wood would be. What is the third dimension (i.e., thickness)? Are we talking about a piece of something like plywood, or something thicker?

What about filling big gaps with polystyrene (styrofoam) blocks and then using bubble wrap to fill in smaller gaps?

I have two possible boxes that I am considering, but I haven't checked the size against the 03 civic IMA battery I am planning to ship. One is a 20x20x17 heavy duty cardboard box from an old (i.e., non flat screen) TV. The other is a plastic shipping container (Monoflo DC2115-17) with inside dimensions of 18.4" x 12.8" x 15.8" (link with photos: https://www.custommhs.com/index.php?...roduct_id=4387).

Does either of these sound adequate, or will I need a bigger box? Any reason it couldn't be shipped upright (i.e. the same orientation it is installed in the civic)?

Thanks in advance for any shipping wisdom you can provide.