How to Pack and Ship Hazardous Materials by Air Freight

Over 1.25 million dangerous goods are shipped by air every year. Because of the risks these materials pose to people, property, and the environment, shipping hazardous materials is strictly regulated. Non-compliance can lead to severe consequences, including hefty fines, shipment delays, and serious safety incidents.

The International Air Transport Association Dangerous Goods Regulations (IATA DGR) are the global standard for shipping hazardous materials by air. Airlines worldwide recognize it as a unified framework that ensures safety, reliability, and compliance.

Keep reading to learn how to classify hazardous materials, meet packaging and labeling standards, prepare documentation, and address common shipping challenges.

What Are Hazardous Materials?

Hazardous materials are items or agents that can endanger health, safety, property, or the environment during transport. Common examples include:

• Flammable liquids (e.g., gasoline, solvents)
• Chemicals (e.g., industrial cleaning agents)
• Lithium batteries (e.g., for electronics)
• Compressed gases (e.g., oxygen tanks)

Proper classification of these materials is the first step toward compliance. Misclassifying them can result in rejected shipments, fines, or safety risks.

Key Regulations for Shipping Hazardous Materials by Air Freight

The IATA Dangerous Goods Regulations (DGR), updated annually, provide guidelines for the safe air transport of hazardous materials. The 66th edition (2025) reflects changes from the International Civil Aviation Organization (ICAO) and the IATA Dangerous Goods Board.

Failure to comply with these regulations can result in:

• Fines and legal penalties
• Shipment delays or rejections
• Safety incidents

The DGR includes details on:

• Applicability – Roles of shippers and operators, plus security, training, and reporting requirements
• Limitations – Restricted materials, transport limits, and rules for postal and passenger shipments
• Classification – Hazard categories like explosives, gases, flammable, toxic, and corrosive materials
• Packing Instructions – Material-specific packaging guidelines
• Packaging Specifications – Requirements for UN-certified packaging, including construction and testing
• Documentation – Forms like the Shipper’s Declaration and Air Waybill (AWB)
• Handling – Storage, inspection, loading, and reporting protocols
• Radioactive Material – Additional rules for transporting radioactive goods

Shippers and freight forwarders are advised to review these changes carefully to maintain compliance.

Packaging Requirements for Hazardous Materials

Safe transport depends on compliant packaging. The IATA DGR and UN certification enforce strict packaging standards to prevent leaks, spills, and other hazards.

What is UN Certification and Why Is It Important?

UN certification ensures that hazardous goods are packaged safely, following the UN Recommendations on the Transport of Dangerous Goods. Many countries require it to meet their regulatory standards.

Key benefits include:

• Protecting People and the Environment – Reduces risks of fires, explosions, and toxic leaks
• Regulatory Compliance – Prevents fines and shipment delays
• Standardization and Efficiency – Simplifies inspections and speeds up the shipping process

Certified packaging must meet material and performance standards. Common materials include metal, plastic, and fiberboard. Packaging undergoes rigorous tests, such as:

• Drop tests to check impact resistance
• Stacking tests to verify structural integrity
• Leak-proof tests to ensure the containment of hazardous substances

Best Practices:

• Use UN-certified packaging appropriate for the material
• Seal containers securely to prevent leaks
• Ensure hazard labels are visible, durable, and compliant

Labeling and Marking Guidelines

Correct labeling is critical to ensure that handlers and inspectors can quickly identify hazardous risks. Labels must be:

• Durable, visible, and legible, placed on the package near shipping marks
• Displayed on a contrasting background, free from obstructions
• Made of weather-resistant material to withstand transport conditions
• Clear and unfaded to maintain compliance

Common hazard labels include:

• Flammable materials – Red diamond with a flame symbol
• Toxic substances – Skull and crossbones symbol
• Corrosive materials – Liquid dripping onto a hand and surface

Labels that deteriorate or are incorrectly applied can result in shipment delays, fines, or safety violations.

Documentation Required for Hazardous Air Freight

Accurate documentation is crucial for shipping hazardous materials. Key documents include:

• Shipper’s Declaration for Dangerous Goods – Details contents, classification, and packaging
• Air Waybill (AWB)
• Packing List
• Material Safety Data Sheet (MSDS), if applicable

Avoid common documentation mistakes, such as:

• Inadequate training
• Incorrect classification of materials
• Improper packaging
• Missing or incorrect labels
• Incomplete or incorrect documentation
• Improper storage and handling
• Failure to comply with international regulations

Proper filing ensures smooth customs clearance and minimizes delays.

Steps to Ensure Safe and Compliant Shipping

To reduce risks of fines, delays, and incidents, follow these steps:

1. Classify the Material – Verify the correct hazardous classification
2. Select the Right Packaging – Use UN-certified packaging appropriate to the material's hazard level
3. Apply Hazard Labels and Markings – Ensure labels are accurate and durable
4. Prepare Documentation – Complete all required forms, including the Shipper’s Declaration
5. Conduct a Compliance Check – Review packaging, labeling, and documents
6. Work with a freight forwarder - Consult experts if necessary

How to Conduct a Pre-Shipment Compliance Review

Conducting a compliance review helps prevent costly errors. Here's how:

• Verify Classification – Confirm the hazardous classification, including the UN number and packing group.
• Check Packaging – Inspect UN-certified packaging for damage and secure seals.
• Inspect Labels – Ensure labels are applied correctly and meet regulatory standards.
• Review Documentation – Cross-check all forms for accuracy.
• Ensure Training Compliance – Verify that personnel have completed the required hazmat training.
• Final Inspection and Approval – Perform a visual check and obtain authorization.

Completing this review helps mitigate risks, prevent regulatory violations, and avoid costly shipment delays or rejections.

Regularly following these steps and conducting compliance reviews ensures safer, more efficient shipping of hazardous materials.

Common Challenges and How to Overcome Them

Despite careful planning, shipping hazardous materials can present unexpected challenges. Here's how to tackle the common issues and keep operations compliant and safe:

1. Regulatory Compliance
   • Adhering to ever-changing regulations is essential to avoid penalties and shipment rejections.
     Tip: Conduct regular compliance audits and stay informed about regulatory updates, including changes to IATA DGR.
   
   


2. Proper Packaging and Labeling
   
   • Incorrect packaging or labeling can lead to shipment delays and fines.
     Tip: Use UN-certified packaging appropriate for the material and ensure hazard labels are visible and durable.
   
   


3. Training and Certification
   
   • Inadequate training is one of the most common reasons for non-compliance and accidents. Employees must understand classification, packaging, labeling, and documentation requirements.
     Tip: Implement regular and ongoing training to ensure personnel remain knowledgeable about evolving regulations and best practices. Refresher courses are key to maintaining compliance and reducing human error.
   
   


4. Risk of Human Error
   
   • Misclassification, documentation errors, or mishandling can result in serious safety risks.
     Tip: Use standardized checklists and pre-shipment compliance reviews to catch and correct errors before shipment.
   
   


5. Security Concerns
   
   • Unauthorized access, theft, or tampering can jeopardize hazardous shipments.
     Tip: Enhance security protocols during loading, storage, and transport. Train staff to detect and report security threats.
   
   


6. Environmental and Public Safety Impact
   
   • Poor handling of hazardous materials can lead to accidents that endanger the environment and public health.
     Tip: Follow emergency response protocols and ensure all safety measures are in place.
   
   


7. Technological and Operational Challenges
   
   • Managing complex documentation and multiple stakeholders can be overwhelming.
     Tip: Implement compliance management tools to streamline communication, documentation, and coordination.
   
   


8. Coordination and Communication
   
   • Misaligned communication between shippers, freight forwarders, and authorities can create delays.
     Tip: Maintain clear and consistent communication across all stakeholders to prevent misunderstandings.
   
   

Overcoming these challenges requires continuous improvement, from refining internal processes to staying informed on regulatory updates. These efforts will ensure safer, more efficient transport of hazardous goods.

Ensure Safe and Compliant Air Freight for Hazardous Materials

Shipping hazardous materials by air requires attention to detail, but with the right processes—accurate classification, secure packaging, proper labeling, and thorough documentation—you can reduce risks, prevent delays, and maintain full compliance.

Whether you manage shipments internally or need expert assistance, proper preparation is key to a smooth process.

Need expert help with hazardous cargo air freight?

Contact iContainers today to get reliable guidance and support for your shipping needs.