Top 10 Hazmat Shipping Violations and How to Avoid Them

A Costly Oversight

It was a Friday afternoon when a logistics manager at a mid-sized manufacturing firm received an urgent call from the Department of Transportation (DOT). A shipment containing flammable paint had been flagged during transit due to missing hazard labels. The result? A $14,500 fine, shipment delays, and a damaged client relationship. All because of one overlooked detail.

This isn’t an isolated story. In 2023 alone, the Pipeline and Hazardous Materials Safety Administration (PHMSA) recorded over 6,300 hazmat shipping violations in the U.S. Many of them were preventable. Here are the top 10 most common hazmat shipping violations and how your business can steer clear of them.

1. Improper Packaging

PHMSA reports that over 20% of hazmat violations stem from using non-compliant packaging. Using the wrong container or damaged drums increases the risk of leaks, contamination, and fines.

How to avoid it: Use DOT-approved containers rated for the specific material class. Check for wear, corrosion, and compatibility.

2. Incorrect or Missing Labels

Hazard class labels are not optional. Missing or wrong labels accounted for nearly 15% of violations in 2023 (DOT Annual Enforcement Summary).

How to avoid it: Match the label with the proper UN number and ensure it's prominently placed and visible.

3. Incomplete Shipping Papers

One in ten violations involves incorrect or missing information on shipping papers.

How to avoid it: Double-check all required details: proper shipping name, hazard class, identification number, packing group, quantity, and emergency contact.

4. Failure to Provide Emergency Response Info

PHMSA requires detailed emergency response information to accompany hazardous materials.

How to avoid it: Include a 24-hour emergency contact and a physical copy of the Emergency Response Guidebook relevant to your material class.

5. Improper Employee Training

Untrained employees are a ticking compliance time bomb. The DOT mandates hazmat training every three years, but 18% of violators in 2023 failed this requirement.

How to avoid it: Provide initial and recurrent training tailored to each employee's role (general awareness, function-specific, security, and safety).

6. Incorrect Use of Placards

Improper placarding is a visual and regulatory failure. This accounts for approximately 9% of reported violations.

How to avoid it: Use the correct placards for the class and amount being transported. Follow the 49 CFR 172.500 placarding rules.

7. Undeclared Hazardous Materials

Failing to declare hazardous materials is among the most severe violations and can lead to criminal penalties.

How to avoid it: Conduct regular internal audits and cross-check product inventories to ensure full disclosure of hazmat content.

8. Improper Markings

Markings such as UN numbers and orientation arrows are mandatory. PHMSA cited over 700 violations due to improper or missing marks in 2023.

How to avoid it: Make sure markings are durable, clearly legible, and placed on the correct sides of the package.

9. Failure to Segregate Incompatible Materials

Mixing incompatible hazardous substances can cause leaks, fires, or explosions during transit.

How to avoid it: Use segregation charts and consult the Emergency Response Guidebook when loading.

10. Non-Compliance with Security Plans

For certain materials, shippers are required to have and follow a security plan.

How to avoid it: If you ship materials in hazard classes 1, 2.1, 2.3, 3, or 6.1, develop a site-specific security plan that meets DOT regulations.

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