HAZMAT shipping 101: Regulations, procedures, and how to ship hazardous materials safely
Shipping hazardous materials—commonly referred to as HAZMAT—comes with strict legal requirements, safety protocols, and carrier-specific guidelines. From lithium batteries in electronics to household cleaning products and aerosol sprays, many ecommerce businesses ship regulated materials without fully realizing the risks and penalties of noncompliance.
Understanding the rules, properly packaging your products, and selecting compliant carriers are all essential to protect your business and your customers. In this guide, we’ll cover everything you need to know to navigate the complexities of HAZMAT shipping safely and legally.
Table of contents
- What is HAZMAT shipping?
- What products are classified as HAZMAT?
- HAZMAT shipping regulations
- Penalties for noncompliance
- How to ship hazardous materials: A step-by-step guide
- Which carriers ship hazardous materials?
- How Pitney Bowes simplifies HAZMAT shipping
- HAZMAT shipping FAQs
What is HAZMAT shipping?
HAZMAT shipping refers to the transportation of goods that the U.S. Department of Transportation (DOT) classifies as hazardous materials. These materials pose risks to health, safety, property, or the environment when transported improperly. Examples include flammable liquids, corrosive chemicals, batteries, and compressed gases.
Carriers such as USPS, UPS, and FedEx have specific procedures and certifications required to ship HAZMAT. Failure to follow these regulations can result in rejected shipments, legal penalties, and potential harm to customers or shipping personnel.
For ecommerce businesses, understanding what qualifies as HAZMAT and following the proper shipping protocols are critical steps in maintaining compliance and ensuring customer safety.
What products are classified as HAZMAT?
Ecommerce businesses, including online retailers in the beauty, electronics, automotive, and home improvement industries, often sell everyday products that fall under HAZMAT regulations. These may include items like hairspray, nail polish remover, and power banks, which require special handling and labeling for shipping compliance. Recognizing these classifications is critical for ensuring safety and avoiding penalties when fulfilling online orders.
Not all hazardous materials are obvious. Everyday consumer products like hairspray, nail polish remover, and power banks often fall under HAZMAT regulations. Some common examples include:
- Batteries (lithium-ion, lithium metal)
- Aerosol sprays (deodorant, hairspray, cooking spray)
- Cleaning chemicals (bleach, disinfectants)
- Flammable liquids (nail polish remover, perfumes)
- Paints and coatings
- Compressed gases (butane, propane)
Before shipping any product, consult the Safety Data Sheet (SDS) or Material Safety Data Sheet (MSDS) to determine if it qualifies as hazardous. You can also refer to the DOT’s Hazardous Materials Table for classification details.
HAZMAT classes explained
Understanding how hazardous materials are categorized is essential for proper packaging, labeling, and carrier selection. Here’s a quick overview of the nine HAZMAT classes:
Class 1: Explosives – Includes fireworks, ammunition, and detonators. Shipping is highly restricted and requires special permits.
Class 2: Gases – Flammable (propane), non-flammable (helium), or toxic gases (chlorine). Must be packaged in certified containers with ventilation considerations.
Class 3: Flammable liquids – Paint thinners, nail polish remover, gasoline. Require leak-proof, flame-resistant packaging.
Class 4: Flammable solids – Includes matches, sulfur, and magnesium. Can ignite through friction or heat.
Class 5: Oxidizers and organic peroxides – Examples include hydrogen peroxide and ammonium nitrate. These can intensify combustion.
Class 6: Toxic and infectious substances – Pesticides, arsenic, or medical specimens fall under this class.
Class 7: Radioactive materials – Medical isotopes, uranium. Very restricted and must be clearly labeled.
Class 8: Corrosives – Products like bleach and hydrochloric acid that degrade other materials upon contact.
Class 9: Miscellaneous dangerous goods – Includes dry ice, lithium batteries, and magnetized materials. Common in ecommerce shipments.
Consult the DOT’s Hazardous Materials Table for full definitions and handling requirements.
HAZMAT shipping regulations
Navigating ecommerce HAZMAT shipping regulations is essential for businesses looking to avoid costly penalties and ensure they are shipping hazardous materials safely. HAZMAT compliance is enforced by multiple agencies, making it critical for ecommerce businesses to follow these guidelines closely.
Shipping hazardous materials in the United States is regulated by the Department of Transportation (DOT) through the Pipeline and Hazardous Materials Safety Administration (PHMSA). Businesses must comply with several layers of regulation to ensure the safe transport of these materials, both for public safety and environmental protection.
In addition to domestic guidelines, international shipments must comply with:
- IATA (International Air Transport Association) – Governs air freight. Requires specific labeling, packaging, and documentation for airline safety.
- IMDG (International Maritime Dangerous Goods Code) – Applies to ocean shipping. Covers classification, stowage, and segregation of hazardous materials aboard vessels.
Penalties for noncompliance
Failing to comply with HAZMAT shipping regulations can have serious consequences. These penalties aren’t limited to large corporations—small and midsize ecommerce businesses are just as vulnerable if they don’t follow proper procedures.
Legal and financial penalties
The U.S. Department of Transportation (DOT) can impose civil penalties of up to $89,678 per violation per day. If the violation results in severe injury, death, or property damage, penalties can increase to $209,249 per violation per day. Criminal charges, including fines and imprisonment, can also apply for willful or negligent misconduct.
Carrier penalties and service bans
Carriers like UPS, FedEx, and USPS may suspend your shipping privileges or impose service bans if you fail to meet their HAZMAT requirements. This can disrupt your fulfillment operations, leading to delayed or canceled customer orders.
Reputation damage
Shipping hazardous materials improperly puts your customers, employees, and carriers at risk. Incidents involving damaged or leaking packages can result in negative press, customer complaints, and loss of brand trust.
Real-world example
In 2022, a well-known online retailer was fined millions of dollars after improperly shipping lithium batteries that caused package fires. This serves as a clear warning that ignoring HAZMAT compliance is not worth the risk—financially or reputationally.
How to ship hazardous materials safely: A step-by-step guide to the HAZMAT shipping process
Shipping hazardous goods demands careful planning, regulatory knowledge, and accurate documentation. Whether you're shipping flammable liquids, corrosive substances, or toxic chemicals, each stage of the HAZMAT shipping process plays a role in protecting people, property, and the environment.
Here’s how to ship regulated materials safely and legally:
- Classify the product – Use the Safety Data Sheet (SDS) to determine the correct hazard class and UN number.
- Use proper packaging – Choose packaging rated for HAZMAT and compatible with your product’s class.
- Label the shipment – Include proper hazard labels, handling instructions, and the UN number.
- Complete required documentation – Include shipping papers, emergency response info, and declarations as required.
- Train your staff – Employees must be trained in HAZMAT regulations, handling, and documentation.
- Choose a compliant carrier – Ensure the carrier is certified and equipped to handle your product’s class.
- Track and store records – Keep detailed shipping records to verify compliance.
Which carriers ship hazardous materials?
Not all shipping carriers accept hazardous materials, and those that do have strict requirements. Here’s what you need to know about major carriers:
USPS
USPS accepts limited types of hazardous materials, such as consumer commodities and ORM-D items, but generally prohibits shipping many HAZMAT items via air services. Businesses must follow USPS Publication 52 for guidelines and secure authorization for certain materials.
UPS
UPS accepts a wide range of hazardous materials, but you must have a UPS HAZMAT agreement and follow their specific packaging, labeling, and documentation requirements. UPS also requires shippers to complete HAZMAT training.
FedEx
FedEx accepts hazardous materials for both ground and air shipments but requires pre-approval. Shippers must comply with FedEx’s guidelines and provide all necessary documentation.
DHL
DHL is a strong choice for international HAZMAT shipping. The carrier complies with both IATA and IMDG standards and accepts a range of regulated materials. DHL requires pre-approval, clear labeling, and proper documentation for all HAZMAT shipments.
How Pitney Bowes HAZMAT shipping solutions for ecommerce businesses make compliance easy
Pitney Bowes offers a comprehensive solution to help businesses safely and efficiently manage hazardous material shipping—from compliance to delivery.
Automated compliance and documentation
Pitney Bowes automates the generation of required paperwork such as shipping papers, declarations, and labels. This reduces manual errors and ensures that documentation is up-to-date with regulations.
Accurate hazardous material labeling
Labels are automatically generated with the correct UN numbers, hazard classes, and emergency response instructions in accordance with DOT, IATA, and IMDG guidelines.
Shipping carrier selection and tracking
Businesses can use Pitney Bowes’ multicarrier platform to choose the best shipping option based on the HAZMAT classification. Real-time tracking ensures visibility across the entire shipping process.
Risk management and reporting
With built-in risk mitigation tools, businesses can monitor shipping trends, flag compliance gaps, and access audit-ready reports to stay ahead of regulatory issues.
International shipping and customs compliance
Pitney Bowes helps businesses comply with global regulations like IATA and the IMDG Code for cross-border shipments of hazardous goods, reducing the risk of delays at customs.
Customized solutions for specific hazards
From flammable liquids to corrosive substances, the platform allows businesses to tailor packaging, documentation, and labeling based on the specific material class.
End-to-end shipment visibility and compliance reporting
Pitney Bowes provides detailed dashboards and automated reports, so businesses can track every shipment’s compliance status and performance across carriers.
HAZMAT shipping FAQs
What is DOT HAZMAT training, and how do I get certified?
DOT HAZMAT training educates employees on how to safely handle, package, and ship hazardous materials. Certification can be completed through online courses or in-person programs and must be renewed every three years.
Can small ecommerce businesses afford to ship HAZMAT?
Yes, but managing costs is key. Using shipping software like Pitney Bowes can help small businesses automate compliance, select cost-effective carriers, and reduce fulfillment overhead.
What should I do if a customer receives a damaged HAZMAT package?
Contact your carrier immediately and report the incident to DOT if required. Review your packaging and labeling process to prevent future issues.
What qualifies as hazardous material?
Hazardous materials include anything classified by the DOT as posing a risk to health, safety, or the environment. Common examples include batteries, aerosols, cleaning chemicals, and flammable liquids.
Do I need special training to ship hazardous materials?
Yes. Anyone involved in packaging, labeling, or shipping hazardous materials must complete DOT HAZMAT training every three years.
Can I ship hazardous materials internationally?
Yes, but international shipments come with additional regulations, including customs documentation, tariffs, and carrier-specific requirements. Check with your carrier and regulatory agencies for guidance.
What happens if I don’t comply with HAZMAT shipping regulations?
Noncompliance can result in severe financial penalties, carrier service bans, and reputational damage. Legal fines can exceed $200,000 per violation per day.
How can Pitney Bowes help with HAZMAT shipping?
Pitney Bowes provides automated compliance checks, carrier selection tools, employee training resources, and ecommerce platform integrations to help businesses navigate HAZMAT shipping safely and efficiently.