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:
The laws for shipping HAZMAT materials vary from country to country. In the United States, the DOT divides hazardous materials into nine classes.
Here’s a breakdown:
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Classes of hazardous materials |
HAZMAT examples |
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Class 1: Explosives |
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Class 2: Gases |
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Class 3: Flammable liquid and combustible liquid |
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Class 4: Flammable solid, spontaneously combustible, and dangerous when wet |
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Class 5: Oxidizer and organic peroxide |
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Class 6: Poison (toxic) and poison inhalation hazard |
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Class 7: Radioactive |
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Class 8: Corrosive |
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Class 9: Miscellaneous |
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For further reference, check the DOT Code of Federal Regulations’ complete Hazardous Materials Table.
As shipping hazardous materials requires careful adherence to regulations and safety standards, you should:
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:
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.
It’s the shipper’s responsibility to pack its items properly. There are three main types of packaging:
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.
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.
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 the 5 benefits of effective carrier contract management.
Compile necessary shipping papers that include a description of the HAZMAT, including:
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:
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.
Shipping HAZMAT can be an operational risk if not executed precisely. While requirements vary by carrier, class, and destination, getting the fundamentals right ensures safe, compliant, and cost-effective movement of goods.
Follow these three best practices to reduce risk exposure, avoid fines, and deliver on customer expectations with confidence.
Misclassification is one of the most common and costly errors in HAZMAT shipping. A centralized classification process ensures that all hazardous substances are correctly identified using the DOT’s nine HAZMAT classes.
To build this process, you should:
Packaging and labeling must comply with strict DOT and carrier-specific rules for shipping hazardous materials. Automated packaging selection, based on material type, weight, and hazard class, removes guesswork from the equation.
System-driven logic should enforce label placement, sizing, and content at the point of fulfillment. For example, hazardous goods shipping that includes lithium batteries requires specific Class 9 markings and label positioning depending on watt-hour ratings.
Blocking non-compliant shipments before label generation protects the customer experience and eliminates penalties.
Regulations require HAZMAT shippers to retain documentation across multiple categories. A digital-first approach ensures access, consistency, and audit readiness.
Most training required under DOT regulations — such as general awareness, safety, and function-specific HAZMAT shipping certification — must be documented and stored for at least three years. Additional records such as shipping papers, incident reports, and special permits must also be retained.
When trying to meet HAZMAT shipping compliance, make sure to consult these 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:
A minimum penalty of $463 also applies to training-related violations.
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 provides shippers with a wide range of options specifically for HAZMAT, including ground and air services. The FedEx HAZMAT shipping requirements are:
Similar to FedEx, UPS provides various options for HAZMAT shipping, such as ground or air methods. Requirements include:
This carrier also provides training and materials on dealing with hazardous items. See the complete UPS HAZMAT shipping requirements in the company’s Guide for Transporting Hazardous Materials.
USPS also ships hazardous materials, and its main requirements are:
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 the 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.
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 it prohibits.
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, selects the best carriers, and provides real-time tracking to reduce transit risks and improve on-time deliveries while avoiding hazardous situations:
Book a demo and see how Shipium can streamline your HAZMAT shipping process.
Hazardous materials — often referred to as HAZMAT — are substances that pose a risk to health, property, or the environment during transport. These materials are regulated by the U.S. Department of Transportation (DOT) under Title 49 of the Code of Federal Regulations (CFR) and classified into nine hazard classes, including flammable liquids, corrosives, explosives, and toxic substances. Accurate classification is the foundation of compliant 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.
Hazardous materials placards are large, diamond-shaped signs placed on the outside of a vehicle, container, or bulk package to visually communicate the presence of these substances during transport.
Each placard corresponds to the specific hazard class of the contents (e.g., Class 3 for flammable liquids). Placarding rules are strictly enforced and vary by quantity, mode of transport, and type of packaging. Proper placarding is essential for shipping compliance and emergency response readiness.
The primary methods of shipping hazardous materials are:
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.
HAZMAT freight shipping has the potential to increase your shipping cost due to:
Learn how to decrease overall shipping costs.
International HAZMAT shipping involves compliance with both domestic and global regulatory frameworks. Shippers must prepare a DG declaration, select approved packaging, apply accurate labels and placards, and ensure that the receiving country’s import regulations are met.
Missteps in HAZMAT shipping across borders can lead to shipment delays, fines, or rejected entries, so alignment between systems, training, and partners is essential for risk-free hazardous goods shipping.