As the ABB FIA Formula E World Championship returns to Shanghai for the 2025/2026 season, DHL has deployed its specialized multimodal logistics framework to manage the global transport behind motorsport’s premier all-electric racing series. Operating as the Official Founding and Official Logistics Partner since 2013, DHL is coordinating cross-border movements for the championship’s largest calendar to date, featuring a record 17 races across 11 cities.
To support the championship’s environmental credentials—which include becoming the first global sports organization to achieve B Corp Certification—DHL coordinates the transport of approximately 400 metric tons of freight per race across air, ocean, rail, and road networks.
Managing High-Risk Lithium-Ion Battery Logistics
The primary technical challenge of Formula E logistics centers on the transport of high-performance lithium-ion batteries. Each race requires moving roughly 31 race-grade battery units, each weighing approximately 400 kilograms. Because these units far exceed consumer battery weight thresholds, they are classified under international transport frameworks as Class 9 dangerous goods.
To maintain strict compliance with International Air Transport Association (IATA) and International Civil Aviation Organization (ICAO) standards, DHL enforces rigorous handling protocols:
Specialized Containment Units: Housing each 400kg battery in certified aluminum containment shells designed to resist thermal runaway and mechanical impact during transit.
State-of-Charge (SoC) Controls: Regulating battery charge percentages prior to loading to comply with aviation safety caps on high-capacity lithium cells.
Non-Stackable Storage Rules: Enforcing strict single-tier floor positioning during air and road legs to prevent compressive stress on battery casings.
Regulatory Clearance Frameworks: Securing specialized hazardous material permits across multiple national customs authorities and aviation boards ahead of race deadlines.
For the Shanghai E-Prix, DHL executed a three-day multimodal transit from Sanya, combining ferry crossings and heavy-haul road transport to meet strict paddock setup schedules without missing race-day deadlines.
Leveraging China’s Battery Supply Chain Network
The race operations reflect broader industrial logistics trends as China continues to serve as the global center for electric vehicle (EV) battery manufacturing and export. Producing over 70% of the world’s lithium-ion batteries and accounting for roughly 60% of global EV battery deployment, China requires extensive outbound logistics networks to move raw materials, battery cells, and complete energy storage systems to international markets.
To support this demand, DHL Global Forwarding China handles over 10,000 TEUs of batteries and related materials annually for export to European and North American manufacturing hubs.
Federico Cavani, Head of Motorsports Italy at DHL Global Forwarding, noted that while Formula E races appear seamless on track, transporting lithium-ion batteries across international borders requires meticulous planning and strict compliance with global standards. He emphasized that the championship demonstrates how complex dangerous goods logistics can be executed safely at scale.
Stephen Zhang, Vice President of Ocean Freight Greater China at DHL Global Forwarding, added that the company partners with major battery manufacturers to deliver end-to-end solutions across the entire supply chain. He highlighted that DHL’s specialized network supports both EV production and the expanding energy storage sector, helping clients manage international export flows safely and efficiently.
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