The global electric vehicle (EV) market is accelerating rapidly, with EVs projected to account for nearly half of all new vehicle sales by 2035. As adoption grows, the pressure on logistics networks intensifies—especially around the transportation, storage, and regulatory management of lithium-ion batteries. Unlike conventional automotive supply chains, EV supply chains introduce new safety risks, compliance obligations, and operational complexities that demand specialised logistics expertise.

For the UAE, which is positioning itself as a regional EV and sustainability hub under national net-zero initiatives, these challenges are amplified by climate conditions, strict dangerous goods regulations, and evolving international compliance standards. Successfully managing EV supply chains today requires far more than standard automotive logistics—it requires precision planning, certified handling, and infrastructure designed for high-risk cargo.

Transporting EV Batteries Safely: A High-Risk Logistics Function

Lithium-ion batteries sit at the core of EV supply chains—and they also represent the greatest logistical risk. These batteries are highly sensitive to physical impact, temperature fluctuations, and improper charging states. Mechanical stress or exposure to excessive heat can trigger thermal runaway, a chain reaction that can cause temperatures to exceed 800°C, resulting in fires that are extremely difficult to contain.

From a logistics perspective, battery transport requires reinforced packaging, impact-absorbing materials, and continuous monitoring throughout the journey. Individual battery packs can weigh more than 400 kilograms, consuming a significant portion of available payload capacity. This added weight reduces transport efficiency, increases the number of required trips, and raises overall logistics costs across inbound and outbound movements.

In the UAE, extreme summer temperatures introduce an additional layer of complexity. Standard dry containers are often unsuitable during peak heat periods, making climate-controlled trucks and refrigerated containers essential for protecting battery integrity during transit. These measures are not optional safeguards—they are operational necessities for safe EV logistics.

Regulatory and Safety Compliance: Navigating a Complex Global Framework

EV battery logistics is governed by a fragmented and constantly evolving regulatory environment. Depending on the transport mode, shipments must comply with ADR (road), IMDG (sea), and IATA/ICAO (air) dangerous goods frameworks. Each system carries its own documentation requirements, packaging instructions, and operational limitations.

In 2025, regulatory pressure has intensified further. Air shipments of lithium-ion batteries are restricted to a maximum 30% State of Charge (SoC), with this same threshold becoming mandatory for batteries shipped with equipment by 2026. Transporting damaged or defective batteries is even more restricted—air freight is typically prohibited, while sea and road movements require specialised containment systems and prior authority approvals.

Within the UAE, compliance extends beyond international standards. Oversight from the Ministry of Industry and Advanced Technology (MoIAT) and the General Civil Aviation Authority (GCAA) introduces local enforcement layers. One commonly overlooked requirement is bilingual dangerous goods labelling—Arabic and English markings are mandatory for all lithium battery shipments entering or transiting the country. Failure to comply can result in immediate shipment holds and financial penalties.

As a result, working with a logistics company in Dubai that understands both global and local compliance frameworks is critical to avoiding delays and safety incidents.

Storage and Handling Challenges in Extreme Climate Conditions

Warehousing EV batteries presents risks that extend well beyond conventional automotive storage. Batteries must be kept within a narrow temperature range—ideally between 15°C and 25°C—to prevent chemical degradation and reduce fire risk. In UAE free zones such as Jebel Ali, authorities increasingly require battery storage facilities to be equipped with specialised fire-suppression systems, continuous thermal monitoring, and controlled access protocols.

Infrastructure strain is another emerging challenge. High ambient temperatures affect charging infrastructure at logistics hubs, slowing charging cycles and increasing downtime. As EV volumes increase, logistics operators must invest in heat-resilient equipment, liquid-cooled charging systems, and power-redundancy planning to maintain operational continuity.

These conditions make battery warehousing one of the most capital-intensive components of EV supply chains—and one that cannot be managed using traditional storage models.

Why EV Supply Chains Demand Specialised Planning

Beyond transport and storage, EV supply chains face structural vulnerabilities. Battery manufacturing and raw material refining remain heavily concentrated in a few geographies, particularly China, exposing global supply chains to geopolitical risk and long lead times. Bringing new lithium mines online can take close to a decade, creating a mismatch between rapid EV model rollouts and material availability.

At the same time, circular economy targets are introducing new logistical responsibilities. End-of-life battery collection, recycling, and second-life deployment are becoming mandatory in many markets, yet standardised reverse-logistics frameworks are still underdeveloped. In the UAE, licensed hazardous-waste specialists are beginning to address this gap, but scalable reverse logistics remains a work in progress.

For logistics providers, these dynamics mean EV logistics must be treated as a specialised vertical—requiring certified staff, purpose-built infrastructure, advanced tracking systems, and legally robust operating procedures. This is particularly true for freight forwarding in Dubai, where EV shipments frequently combine international transit, free-zone storage, and last-mile coordination under strict compliance timelines.

The Strategic Role of UAE Logistics Providers

As EV adoption accelerates across the Middle East, the UAE is emerging as a critical gateway for regional EV distribution. A professional shipping and logistics company in Dubai plays a pivotal role in enabling this growth by bridging global regulatory standards with local operational realities.

Logistics partners that invest early in battery handling certification, climate-controlled infrastructure, and digital compliance tools will gain a decisive advantage. Opportunities are also expanding in reverse logistics, battery repurposing for energy storage projects, and fleet electrification—supported by government incentives such as toll exemptions and reduced registration fees.

Conclusion

Electric vehicle supply chains are redefining the logistics landscape. The risks associated with lithium-ion batteries, the complexity of global and UAE-specific regulations, and the operational demands of extreme climate conditions make EV logistics one of the most challenging segments in modern supply chains.

Success in this sector depends on specialised planning, certified handling, and infrastructure designed specifically for high-risk cargo. For businesses operating in or through the UAE, partnering with experienced logistics providers is no longer a strategic option—it is a commercial necessity.

By mastering safety, compliance, and environmental constraints, the logistics sector can play a central role in supporting the region’s transition toward sustainable mobility and long-term economic resilience.