HAZMAT Shipping Compliance: A Guide

From medical supplies to industrial chemicals, shipping hazardous materials (HAZMAT) requires a deep understanding of regulatory requirements. The process is complex — and for good reason. Each year, according to research from the U.S. Department of Transportation (DOT), approximately 1,500 incidents occur involving undeclared materials — including fires, leaks, and explosions that endanger logistics workers and disrupt the supply chain.

Case in point: a recent explosion at a port in China involving mis-declared cargo has further intensified discussions around safety in shipping dangerous goods, pushing leaders to reassess operational risks. Let’s explore the essentials of HAZMAT shipping to help operators navigate this logistics scenario effectively.

Key takeaways:

• Regulations for shipping HAZMAT materials are strict, and noncompliance is expensive — violating requirements can result in fines of up to $179,933 for serious offenses, including injuries, property damage, or fatalities​.

• Hazardous materials are categorized into nine classes. Improper labeling or documentation is one of the most common HAZMAT shipping compliance violations, leading to shipment rejections and delays.

• Using AI-driven logistics solutions like Shipium helps businesses automate tasks, optimize carrier selection, and prevent costly mistakes in HAZMAT freight shipping.

What are the main types of shippable hazardous materials?

The laws for shipping HAZMAT materials vary from country to country. In the United States, the DOT divides hazardous materials into nine classes.

Source: U.S. Department of Transportation

Here’s a breakdown:

For further reference, check the DOT Code of Federal Regulations’ complete Hazardous Materials Table.

How to ship HAZMAT

As shipping hazardous materials requires careful adherence to regulations and safety standards, you should:

1. Classify the material

Before shipping HAZMAT, companies must classify them according to regulations. Look up your product’s Safety Data Sheet (SDS). Most reputable consumer products have an SDS outlining their hazard classification. 

This identification includes:

• A four-digit ID number
• The proper shipping name 
• The hazard class
• The packing group

Use this information to locate the appropriate entry in the DOT’s Hazardous Materials Table. All other requirements, including packaging, labels, and shipping papers, are based on a product’s classification.

2. Use appropriate packaging

It’s the shipper’s responsibility to pack its items properly. There are three main types of packaging:

• Single packaging: A single barrier to contain the hazardous material. Common forms include pails, drums, kegs, and jerricans.

• Combination packaging: One or more inner packages secured within an outer one. The inner packages can be of different types or sizes, allowing for flexibility in shipping multiple items together. 

• Composite packaging: An inner receptacle placed inside a durable outer package. Unlike combination packaging, the two can’t be separated when handled.

The packaging requirements for HAZMAT products also vary based on the material type. For example, while dangerous liquids are best suited for drums, the type of liquid can dictate whether they need to be stored in steel, aluminum, or plastic drums. Check DOT’s complete guide for packaging and its code requirements.

3. Label your packages correctly

Classification ultimately doesn’t matter if your products aren’t clearly labeled — without the right HAZMAT shipping labels, anyone handling the package won’t know the risks involved. 

Apply the correct labels, such as orientation arrows, identification numbers, and hazard class markings. Inappropriate labeling is one of the most frequent mistakes shippers commit, and the U.S. Department of Transportation has created a guide to identifying and understanding packaging labels.

4. Contact carrier partners

Contact carriers in your network and verify their handling processes, certifications, and specific transportation requirements for hazardous materials. With a carrier management system like Shipium, this process becomes automated, allowing businesses to match shipments with the most qualified carriers based on product characteristics, regulatory requirements, and cost efficiency.

Learn 5 benefits of effective carrier contract management.

5. Prepare hazmat shipping papers

Compile necessary shipping papers that include a description of the HAZMAT, including:

• UN identification number
• Proper shipping name
• Hazard class
• Packing group
• Quantity and type of packages
• Emergency contact information
• Shipper’s certification

6. Invest in training and certification

To guarantee hazardous material shipping compliance, all individuals involved in the handling, packaging or transportation of such materials must complete HAZMAT training within 90 days of employment or a change in job function. Those include transport and warehouse personnel. They are also required to undergo refresher training every three years to comply with DOT regulations.

The DOT offers training programs through its Office of Hazardous Materials Safety (OHMS). As well, they offer free online training modules that cover numerous essential topics such as:

• The Hazardous Materials Table
• Shipping papers
• Marking and labeling
• Security requirements

For additional information, contact the U.S. Hazardous Materials Information Center by telephone at 1-800-467-4922 or by e-mail at infocntr@dot.gov.

Regulations for shipping hazardous materials

When trying to meet HAZMAT shipping compliance, make sure to consult these regulations:

• U.S. Code of Federal Regulations, Title 49: The primary focus of this regulation is ensuring safe transportation across multiple modes — from road, rail and air, to waterways. This set of norms includes specificities for transporting hazardous materials and details requirements for packaging, labeling, documentation, and emergency response protocols.

• International Maritime Dangerous Goods Code (IMDG): Initially adopted in 1965, the IMDG Code became mandatory under the International Convention for the Safety of Life at Sea (SOLAS) on January 1, 2004. Compliance with the IMDG Code is required for all maritime transport of dangerous goods.

• International Air Transport Association Code (IATA): This dangerous goods regulation sets requirements for transportation through air, including the use of UN-approved containers, construction standards, and testing protocols to make sure packages can withstand the rigors of air transport.

Penalties for non-compliance with HAZMAT regulations

The U.S. DOT specifies fines of up to $77,114 per HAZMAT shipping violation, depending on the nature and severity of the offense. Penalties increase to a maximum of $179,933 if the violation results in:

• Death
• Serious illness
• Severe injury to a person
• Substantial property destruction

A minimum penalty of $463 also applies to training-related violations.

HAZMAT shipping requirements for nationwide carriers

Beyond federal and international regulations, sending hazardous materials by any means of transportation also means following the requirements of the carrier’s state to avoid risks and financial losses. 

Let’s review the main requirements for nationwide carriers:

FedEx

FedEx provides shippers with a wide range of options specifically for HAZMAT, including ground and air services. The FedEx HAZMAT shipping requirements are:

• Companies must contact a FedEx Account Executive to become an approved hazardous materials shipper.

• All packages must be properly classified, described, packaged, marked, and labeled according to the Code of Federal Regulations.

• The company offers shippers a training program and HAZMAT shipping certification. Read the complete FedEx hazardous materials guide.

UPS

Similar to FedEx, UPS provides various options for HAZMAT shipping, such as ground or air methods. Requirements include: 

• Ground service level packages must comply with Title 49 of the Code of Federal Regulations. 

• For air services, packages must be prepared in accordance with either the U.S. DOT norms or the IATA dangerous goods regulations.

This carrier also provides training and materials on dealing with hazardous items. See the complete UPS HAZMAT shipping requirements on the company’s Guide for Transporting Hazardous Materials.

USPS

USPS also ships hazardous materials, and its main requirements are:

• Shippers must declare if they are sending HAZMAT materials when creating a shipping label. This is done through the shipping software, such as Shipium, where you must select the option indicating that the shipment contains hazardous materials.

• Packages must display HAZMAT labels that indicate the primary hazard class or division of the material being shipped. These labels need to be prominently placed to ensure quick visual identification by USPS staff. 

There are some restrictions for domestic and international shipments, though. The company prohibits sending items such as glues, matches, aerosols, and any perishable items through mail. Shippers can use the USPS HAZMAT Tool to assess whether their item is considered hazardous and to find specific packaging instructions tailored to their product.

USPS also provides a tutorial on HAZMAT Shipping Safety.

DHL

To ship with DHL, companies must go through an approval process. DHL also requires a Material Safety Data Sheet (MSDS). This document lays out detailed information about the chemical composition and hazards associated with the materials, ensuring compliance with international shipping laws.

Check DHL’s guide to shipping dangerous goods to view the list of items the carrier accepts and those they prohibit.

Ship hazardous materials safely with Shipium

Shipping dangerous goods is a high-stakes process. Even minor errors can lead to severe fines, shipment delays, and safety hazards. While compliance is critical, managing multiple regulations, carriers, and documentation can be overwhelming. But with an end-to-end shipping management platform like Shipium, you can automate and optimize your fulfillment process. 

By integrating with your existing systems, like your OMS and WMS, Shipium ensures regulatory compliance, select the best carriers, and provide real-time tracking to reduce transit risks and improve on-time deliveries while avoiding hazardous situations:

• Shipium Simulation analyzes past shipment data to identify bottlenecks, allowing businesses to adjust fulfillment services before problems arise.

• Carrier selection enables HAZMAT shipments to move through the most reliable and compliant transportation networks.

• Accurate delivery promises and real-time tracking improves efficiency and reduces the likelihood of disruptions.

Book a demo and see how Shipium can streamline your HAZMAT shipping process.

Frequently asked questions

What is HAZMAT shipping?

HAZMAT shipping refers to the transportation of hazardous materials that pose potential risks to health, safety, property, and the environment if not properly handled or stored. These materials can include chemicals, corrosive substances, ammunition, and even everyday items like batteries or aerosol sprays. Their shipping process is highly regulated to ensure safety and compliance with government norms.

How long does HAZMAT shipping take?

Timeframes for Shipping HAZMAT depend on various factors, such as carrier approval, specialized documentation, and safety inspections before transit, which can extend shipping times.

Shipping HAZMAT with FedEx or UPS per ground, for instance, typically takes 1-5 business days, depending on the distance, while air services can be quicker but are subject to additional regulations and handling times.

Does shipping hazardous materials increase logistics costs?

HAZMAT freight shipping has the potential to increase your shipping cost due to:

• Safety measures: Special packaging, labeling, or handling may be required to prevent leaks or spills, adding fees to your shipment.

• Specialized handling: Training personnel can incur additional costs, including labor hours and certification requirements.

• Carrier fees: Additional charges may be added based on the type of hazardous material — FedEx, for example, charges around $160 per package for accessible dangerous goods.

Learn how to decrease overall shipping costs.