Hazmat Shipping Guide: Regulations and Compliance for E-commerce

Shipping hazardous materials (hazmat) requires strict compliance with federal regulations. Many common e-commerce products—batteries, perfumes, nail polish, aerosols—are classified as hazmat. This guide helps sellers understand requirements and ship safely.

What Qualifies as Hazmat?

Common E-commerce Hazmat Products

Batteries:

• Lithium-ion batteries (phones, laptops, power banks)
• Lithium metal batteries
• Lead-acid batteries
• Battery-powered devices

Flammable liquids:

• Perfumes and colognes
• Nail polish and remover
• Hand sanitizers (high alcohol)
• Essential oils
• Lighter fluid

Aerosols:

• Spray paints
• Hairspray and deodorants
• Cleaning products
• Air fresheners
• Pepper spray

Other common items:

• Matches and lighters
• Dry ice
• Ammunition
• Fireworks
• Pool chemicals
• Pesticides

Nine Hazmat Classes

Class 1: Explosives

• Fireworks, ammunition, flares

Class 2: Gases

• Aerosols, compressed gases, propane

Class 3: Flammable Liquids

• Perfumes, nail polish, alcohol-based products

Class 4: Flammable Solids

• Matches, magnesium, certain metals

Class 5: Oxidizers

• Pool chemicals, bleach, hydrogen peroxide

Class 6: Toxic/Infectious

• Pesticides, medical waste

Class 7: Radioactive

• Medical isotopes, smoke detectors

Class 8: Corrosives

• Battery acid, drain cleaners

Class 9: Miscellaneous

• Lithium batteries, dry ice, magnetized materials

Regulatory Framework

Key Agencies

DOT (Department of Transportation):

• Primary hazmat transportation regulator
• 49 CFR regulations
• Training requirements
• Packaging standards

PHMSA (Pipeline and Hazardous Materials Safety Administration):

• DOT sub-agency
• Specific hazmat rules
• Enforcement authority
• Guidance documents

FAA/IATA:

• Air transport regulations
• Stricter than ground rules
• International standards
• Airline-specific restrictions

USPS/Carrier Rules:

• Additional restrictions
• Service limitations
• Acceptance criteria
• Packaging requirements

Understanding 49 CFR

What it covers:

• Material classification
• Packaging requirements
• Labeling and marking
• Documentation (shipping papers)
• Training requirements
• Incident reporting

Lithium Battery Shipping

Why Batteries Are Complex

Safety concerns:

• Fire risk during transport
• Thermal runaway possibility
• Pressure from altitude (air)
• Damage during handling

Battery Classification

UN3480: Lithium-ion batteries (standalone) UN3481: Lithium-ion batteries packed with/in equipment UN3090: Lithium metal batteries (standalone) UN3091: Lithium metal batteries packed with/in equipment

Shipping Requirements

For lithium-ion under 100Wh:

• Most carrier-friendly
• Ground and limited air options
• Proper packaging required
• Mark and label correctly

Key requirements:

• State of charge: 30% or less (standalone)
• Individual protection from short circuit
• Strong outer packaging
• UN specification marks
• Proper shipping documentation

Carrier-Specific Rules

USPS:

• Domestic ground: Generally accepted
• Domestic air: Restrictions apply
• International: Limited acceptance
• Requires hazmat training for some

UPS:

• Accepts most lithium batteries
• Requires proper declaration
• Special packaging for bulk
• Ground service preferred

FedEx:

• Similar to UPS requirements
• Online certification available
• Ground and limited air
• Specific packaging standards

Flammable Liquid Shipping

Common Products

Cosmetics and personal care:

• Perfumes (flash point matters)
• Nail polish (Class 3)
• Hand sanitizers (60%+ alcohol)
• Aftershaves

Household products:

• Lighter fluid
• Paint thinners
• Certain cleaners
• Automotive fluids

Shipping Requirements

Limited quantity exception:

• Under specific thresholds
• Reduced packaging requirements
• Simplified documentation
• Ground service typically

Inner packaging limits:

• Usually 1 liter or less
• Combined total limits
• Strong outer package
• Absorbent material

Proper Packaging

Requirements:

• Leak-proof inner containers
• Absorbent material
• Strong outer box
• Orientation arrows
• Limited quantity marking

Aerosol Shipping

Understanding Aerosol Hazards

Why aerosols are hazmat:

• Pressurized containers
• Often contain flammable propellants
• Risk of rupture
• Temperature sensitivity

Classification Levels

Level 1: Non-flammable (easiest to ship) Level 2: Flammable (flash point > 20°C) Level 3: Highly flammable (most restricted)

Shipping Options

Ground shipping:

• Most aerosols accepted
• Proper packaging required
• Quantity limits apply
• Limited quantity option

Air shipping:

• Highly restricted
• Many carriers refuse
• Special authorization needed
• Passenger vs. cargo aircraft

Packaging Requirements

UN Specification Packaging

When required:

• Full hazmat shipments
• Above limited quantities
• Air transportation
• International shipments

Types:

• UN4G: Fiberboard boxes
• UN4GV: Combination packaging
• Tested to DOT standards
• Certified markings required

Limited Quantity Packaging

Requirements:

• Strong outer packaging
• Inner package limits met
• Combination limits met
• Proper marking

Marking:

• Diamond-shaped mark
• Black or red border
• Specific dimensions
• Proper placement

Consumer Commodity (ORM-D)

Being phased out:

• Replaced by limited quantity
• Some acceptance continues
• Check carrier requirements
• Use limited quantity when possible

Labeling and Marking

Hazmat Labels

Required labels by class:

• Class 1: Orange explosion
• Class 2: Green gas cylinder
• Class 3: Red flame
• Class 8: Black/white corrosive
• Class 9: White/black stripes

Package Markings

Required markings:

• Proper shipping name
• UN identification number
• Shipper name and address
• Consignee information
• Orientation arrows (if needed)

Limited Quantity Mark

Specifications:

• Diamond shape
• 100mm x 100mm minimum
• Black border (2mm minimum)
• Y symbol inside (air transport)

Documentation Requirements

Shipping Papers

Required information:

• Proper shipping name
• Hazard class/division
• UN/NA number
• Packing group
• Total quantity
• Emergency contact

Shipper's Declaration

For air transport:

• IATA shipper's declaration
• Detailed information
• Signatures required
• Original copies needed

Record Keeping

Retention requirements:

• Shipping papers: 2 years
• Training records: 3 years
• Incident reports: As required
• Test certificates: Varies

Training Requirements

Who Needs Training?

Required for:

• Anyone shipping hazmat
• Package preparers
• Documentation creators
• Supervisors of hazmat operations

Training Types

General awareness:

• Understanding regulations
• Material recognition
• Basic safety

Function-specific:

• Job-related requirements
• Packaging procedures
• Documentation completion

Safety training:

• Emergency procedures
• Personal protection
• Spill response

Security awareness:

• Threat recognition
• Security protocols
• Reporting procedures

Training Resources

Free options:

• PHMSA online resources
• Carrier training programs
• Industry webinars

Paid options:

• DOT-approved courses
• Certification programs
• Carrier-specific training

Carrier Restrictions

USPS Restrictions

Cannot ship:

• Most Class 1 (explosives)
• Flammable gases
• Toxic substances
• Infectious substances

Limited acceptance:

• Small lithium batteries
• Limited quantity liquids
• Consumer commodities
• Ground service only for most

UPS and FedEx

Generally accept:

• Most ground hazmat
• Properly packaged materials
• Documented shipments
• Trained shipper requirements

Restrictions:

• Air service limitations
• Quantity limits
• Certain materials prohibited
• International restrictions

Ground-Only Carriers

Regional carriers:

• Often more restrictive
• Check before shipping
• Service limitations
• Local regulations apply

International Hazmat Shipping

Additional Requirements

IATA regulations:

• Stricter than domestic
• Specific packaging
• Declaration requirements
• Airline acceptance

Country-specific rules:

• Import restrictions
• Documentation requirements
• Labeling differences
• Prohibited items vary

Common Challenges

International issues:

• Customs delays
• Different classifications
• Language requirements
• Higher costs

Penalties for Non-Compliance

Civil Penalties

DOT violations:

• Up to $96,624 per violation
• Per day penalties possible
• Inspection findings
• Documentation failures

Criminal Penalties

For willful violations:

• Up to $500,000 fines
• Up to 10 years imprisonment
• Enhanced for death/injury
• Corporate liability

Carrier Consequences

Shipper violations:

• Service suspension
• Account termination
• Claims denial
• Legal liability

Best Practices for E-commerce Sellers

Product Assessment

Identify all hazmat products

Determine classification

Check carrier acceptance

Plan shipping methods

Operational Setup

Train relevant staff

Stock compliant packaging

Create standard procedures

Document everything

Shipping Process

Verify classification before each shipment

Use proper packaging

Complete documentation correctly

Choose appropriate carrier/service

Record Keeping

Maintain training records

Keep shipping documents

Track compliance issues

Regular audits

Alternative Options

Fulfillment Providers

Benefits:

• Expertise in hazmat
• Compliant facilities
• Trained staff
• Shared liability

Specialized Carriers

Hazmat-focused carriers:

• Better rates for hazmat
• Expert handling
• Full compliance
• Wider acceptance

Product Reformulation

Consider:

• Non-hazmat alternatives
• Lower concentrations
• Different packaging
• Solid vs. liquid forms

Key Takeaways

Know your products: Identify all hazmat items in inventory

Understand classifications: Proper class determines requirements

Training is mandatory: Required for anyone handling hazmat

Packaging matters: Use proper, compliant packaging

Document everything: Complete shipping papers correctly

Choose carriers wisely: Not all accept all hazmat

Stay updated: Regulations change regularly

Consider alternatives: Sometimes reformulation or 3PL makes sense

Shipping hazmat legally protects your business and keeps transportation workers safe. While compliance requires effort, the penalties for violations—and the risks of incidents—make proper procedures essential for any seller handling hazardous materials.