USPS Hazardous Materials Shipping Rules

Introduction

Navigating the complex web of regulations surrounding the shipment of hazardous materials (hazmat) through USPS can be daunting for many shippers. Surprisingly, everyday items like electronics with lithium batteries, alcohol-based perfumes, and aerosols are classified as hazardous. These products are subject to strict rules set by the Department of Transportation (DOT) and USPS. Non-compliance can lead to hefty fines and even criminal charges. This guide will help demystify the rules, explaining what qualifies as hazardous materials, USPS's specific restrictions, and the essential packaging and labeling requirements for various product categories, including batteries, cosmetics, and aerosols.

What Qualifies as Hazardous Materials?

The DOT categorizes hazardous materials into nine classes based on their physical and chemical properties. Understanding these categories is crucial for compliance.

DOT Hazard Classes

Explosives: This includes items like fireworks, ammunition, and flares. These materials pose significant risks due to their potential to combust or explode.

Gases: Examples are propane, butane, and aerosol sprays. These gases are often under pressure and can be hazardous if leaked.

Flammable Liquids: This class encompasses gasoline, alcohol, nail polish, and perfume. These substances are easily ignited and require special handling.

Flammable Solids: Items such as matches and magnesium fall into this category. They can ignite through friction or contact with air.

Oxidizers & Organic Peroxides: Common household items like bleach and hydrogen peroxide are included here. They can cause or enhance combustion of other materials.

Toxic & Infectious Substances: Pesticides and certain medical specimens are examples. These materials can pose health risks upon exposure.

Radioactive Materials: While most are prohibited, items like smoke detectors contain small amounts of radioactive material.

Corrosives: Batteries (especially wet ones) and acids are key examples. They can cause severe damage to living tissue or other materials.

Miscellaneous: This includes items like lithium batteries and dry ice, which don't fit neatly into the other categories but still pose risks.

The Key Distinction: Forbidden vs Restricted vs Permitted

USPS classifies hazmat shipments into three categories: forbidden, restricted, and permitted.

• Forbidden: These items can't be shipped under any circumstances. This includes explosives, poison gases, most radioactive materials, and fireworks.
• Restricted: These can be shipped under specific conditions. For instance, lithium batteries are allowed when properly packaged, aerosols as consumer commodities, and perfumes in limited quantities.
• Permitted: These are items with negligible hazmat properties, like household goods and non-regulated batteries.

Lithium Battery Shipping Rules

Lithium batteries are a common component in electronic devices but come with unique shipping challenges. USPS has specific guidelines depending on how the batteries are shipped.

Battery Types and Configurations

Contained in Equipment: Batteries installed within a device, such as a smartphone or laptop. These are generally easier to ship as the device provides additional protection.

Packed with Equipment: Batteries shipped alongside the device but not installed. For example, a camera with a replacement battery.

Standalone Batteries: Batteries shipped without any device. These require the most careful packaging to prevent short circuits or damage.

USPS Lithium Battery Rules

• Small Lithium-ion Batteries (≤100Wh): Can be shipped by all services if contained within equipment. If packed with or standalone, they must go by ground.
• Medium Lithium-ion Batteries (100-300Wh): Ground shipping only if contained within equipment; otherwise, they are forbidden.
• Large Lithium-ion Batteries (>300Wh): Forbidden across all services due to the higher risk of overheating and fire.
• Small Lithium Metal Batteries (≤1g lithium per cell): Similar to small lithium-ion batteries in terms of shipping options.

What Counts as "Small"?

For practical purposes, most consumer electronics fall into the small category. For example, a smartphone battery is typically around 10-15Wh, while a power bank might be about 37Wh. These can be shipped more easily with appropriate packaging.

Packaging Requirements for Lithium Batteries

Proper packaging is crucial to ensure safety during transit:

Protect Terminals: Use non-conductive tape or covers to prevent short circuits.

Prevent Movement: Secure batteries within the package to avoid shifting.

Strong Outer Packaging: Choose a durable box that can withstand normal handling.

Individual Protection: Place each battery in its own protective sleeve or compartment.

No Damaged Batteries: Do not ship batteries that are swollen, leaking, or damaged.

Required Markings for Lithium Batteries

Packages must display a DOT lithium battery mark, including the UN number (UN3481 for lithium-ion, UN3091 for lithium metal) and the shipper’s contact information. The mark should be prominently visible on the package.

Aerosol Products (Spray Cans)

Aerosol products, classified as Class 2 hazardous materials, can be shipped via USPS under certain conditions.

Consumer Commodity Aerosols

Most consumer aerosol products fall under "Consumer Commodities," allowing them to be shipped by ground services if properly packaged.

• Service: Ground transport only.
• Quantity per Package: Maximum of 24 oz per can and 72 oz total per package.
• Packaging: Cans must be upright and protected from puncture.
• Marking: Use "Consumer Commodity ORM-D" or the limited quantity mark.

Common Aerosol Products

Consumer aerosols like hairspray, spray paint, and cooking sprays are generally permissible for ground shipping. However, industrial aerosols and items like bear or pepper spray are not mailable.

Perfumes, Colognes, and Alcohol-Based Products

Fragrances with alcohol are Class 3 hazardous materials, and USPS allows them in limited quantities.

Rules for Shipping Fragrances

• Container Limit: Up to 16 fl oz per container.
• Package Limit: Up to 1 gallon total.
• Packaging: Use leak-proof containers with absorbent material and secure outer boxes.
• Transport: Ground only for quantities greater than 1 fl oz; air transport allowed for very small quantities.

Packaging Requirements for Fragrances

Secure packaging is essential:

Inner Container: Must be leak-proof with a secure closure.

Absorbent Material: Sufficient to absorb the entire content of any broken container.

Cushioning: Protect glass bottles to prevent breakage.

Outer Box: Use a sturdy, corrugated box to withstand transit.

Marking: Indicate "Surface/Ground Transportation Only" when applicable.

Nail Polish and Cosmetics

Nail polish and removers are Class 3 hazardous materials due to their flammable nature.

Shipping Rules

Nail polishes can be shipped with certain limitations, while nail polish removers are more restricted.

• Ground Transport: Permissible with limited quantities.
• Air Transport: Allowed for nail polish only, and in very small quantities.

Quantity Limits

• Ground Transport: Up to 1 pint per inner container and 1 gallon per package.
• Air Transport: Limited to containers of 1 fl oz or less.

Dry Ice

Dry ice is often used as a refrigerant for perishable goods and can be shipped with USPS under specific conditions.

Dry Ice Rules

• Weight Limit: Maximum of 5 lbs per package.
• Service: Permitted for all services, including air.
• Purpose: Only for refrigerating non-hazmat contents.
• Packaging: Must allow for gas ventilation to prevent pressure buildup.
• Marking: Label as "Dry Ice" or "Carbon Dioxide, Solid," and indicate weight in kilograms.

Important Dry Ice Safety

Ensure that the packaging allows for gas escape to prevent pressure buildup. Avoid completely sealing Styrofoam coolers and clearly label all sides with "DRY ICE."

Ammunition and Firearms-Related Items

Shipping ammunition and firearms-related items requires careful adherence to USPS rules.

Small Arms Ammunition

• Shippable Conditions: Small arms ammo can be shipped ground under Consumer Commodity ORM-D, with a maximum weight of 66 lbs.
• Packaging: Must prevent movement and accidental discharge. Use strong corrugated boxes.

Key Rules for Ammunition

Ammunition must be shipped using ground services only and properly labeled. Ensure that cartridges are secure and immobile within the package.

Compliance and Penalties

Shipping non-compliant hazmat items can lead to severe penalties.

What Happens If You Ship Prohibited Items?

USPS enforces strict penalties for violations, including fines up to $500,000 and possible imprisonment for willful violations. Packages are screened via X-ray and physical inspection, and suspicious items are flagged and audited.

How to Stay Compliant

Product Knowledge: Review Safety Data Sheets (SDS) to understand product classifications.

Staff Training: Ensure everyone handling shipments is aware of rules and procedures.

Proper Packaging: Follow USPS guidelines for each hazmat category.

Correct Marking: Apply necessary labels and markings.

Service Selection: Use ground-only services when required by regulations.

Documentation: Keep detailed records of all hazmat shipments.

Consult Experts: When unsure, contact USPS or a hazmat consultant.

Common E-Commerce Products and Their Hazmat Status

Many online sellers unwittingly deal with hazmat items. Here's a quick reference guide:

• Smartphones and Laptops: Contain lithium batteries, shippable under conditions.
• Power Banks: Shippable via ground only; air transport is restricted.
• Essential Oils and Hand Sanitizers: May be flammable; check individual flash points and SDS.
• Candles and Lotions: Generally non-hazmat and shippable via all services.
• Spray Paint and Cleaning Products: Often flammable; check quantity limits and SDS for compliance.

Shipping hazardous materials with USPS demands careful attention to regulations, but most consumer products can be sent without issue by adhering to guidelines. For e-commerce sellers, the most common hazmat items are lithium batteries and flammable liquids, both of which are manageable with proper precautions. Compliance is crucial, as violations carry significant penalties and safety risks. Always check product SDS and USPS Publication 52 for updates and consult experts when in doubt.