Miss one step in dangerous goods prep and the shipment stalls. Carriers refuse loads, rework costs spike, and customer commitments slip. This guide separates the four tasks that get confused most often. Use this guide to help your team ship safely, pass audits, and keep products moving.
The Four Jobs, Plain and Simple
- Packaging protects the contents and meets a tested performance standard. Think about UN-rated boxes, drums, and inner packs selected to the right Packing Group.
- Marking identifies what is inside the package. These are words and numbers printed or affixed to the outer package.
- Labeling communicates the hazard class on the package. These are the diamond-shaped hazard labels that visually identify what type of Hazmat is inside the box(es) .
- Placarding communicates hazards for the vehicle or container. These are large diamonds on the exterior of the conveyance moving your shipment like trailers, containers, and tankers.
Each step serves a different audience: packaging protects handlers and product, marking and labeling inform small-parcel, freight forwarders, and other carriers, and placards guide first responders and DOT roadside inspections.
Packaging: Performance First
Goal: Select packaging that has been tested for the commodity and packing group.
What matters:
- UN performance packaging matched to the material’s Packing Group I, II, or III and state of matter.
- Inner containment to prevent leaks or contact between incompatible items.
- Absorbents and cushioning where required for liquids or fragile inner receptacles.
- Closure instructions from the packaging manufacturer followed exactly, including number of tape wraps, torque on caps, and specific liners.
Common misses:
- Using non-UN boxes for materials that require UN-rated packaging.
- Ignoring closure instructions and losing the certification.
- Mixing incompatible inners in the same outer without required segregation.
Quick win: Document the closure steps on a one-page work instruction and post it at the pack-out station.
Marking: Make Identification Unambiguous
Goal: Tell anyone handling the box exactly what it is and how much is inside.
Core marks you may need:
- UN number and Proper Shipping Name (for example: UN 1993, Flammable liquids, n.o.s.)
- Full shipper and consignee names and addresses
- Gross weight where required
- Orientation arrows for liquid inner packaging
- Limited Quantity or Excepted Quantity marks when those provisions apply
- Overpack mark when combining marked packages in a single enclosure
Common misses:
- Forgetting the UN number or abbreviating the Proper Shipping Name.
- Applying stretch-wrap over marks so they are not legible.
- Missing Overpack marks when combining multiple marked boxes.
Quick win: Place marks on two opposing sides, clear of seams and straps, and apply after wrapping.
Labeling: Communicate the Hazard Class
Goal: Use standardized hazard labels so handlers recognize the risk at a glance.
Label basics:
- Primary hazard label according to the hazard class or division.
- Subsidiary risk labels if applicable.
- Minimum size and contrast standards so labels remain legible in transit.
- Placement on the same face near the markings without overlap.
Common misses:
- Using only the primary label and skipping a required subsidiary risk.
- Placing labels over corners or tapes that peel in transit.
- Using old labels with inferior or dried out adhesive
- Incorrect lithium battery mark or mixing old and current formats.
Quick win: Keep a printed matrix at pack-out showing which classes need subsidiary labels and when the lithium mark applies.
Placarding: Vehicle and Container Communication
Goal: Identify hazards for transport units at a distance.
When placarding is used:
- Highway and rail movements at, or above, threshold quantities.
- Intermodal containers and tankers per quantity and class rules.
- Limited Quantity and Excepted Quantity provisions that may change placard needs.
Common misses:
- Assuming package labels replace vehicle placards. They do not.
- Using small package marks in place of placards on containers.
- Missing placards after transload or cross-dock.
Quick win: Add a placard verification step at trailer seal or container handoff. Take a photo as it leaves the dock.
Mode Matters: Air, Ocean, and Ground Differences
- Air (IATA DGR): Tight limits on quantities, special provisions for lithium batteries and magnetized materials, and strict package testing and documentation.
- Ocean (IMDG Code): Stowage and segregation drive planning. Container packing certificates and dangerous goods manifests must match what is on the doors.
- Road and Rail (49 CFR in the U.S., TDG in Canada): Shipping papers, emergency response numbers or plans, and placard thresholds are the focus.
Practical tip: Build one master data sheet per SKU with UN number, Proper Shipping Name, packing group, hazard class, limited quantity eligibility, and mode-specific limits. Use it to drive labels, marks, and documents.
A Simple, Repeatable Workflow
- Start with the SDS and verify the UN number, Proper Shipping Name, class, and packing group.
- Select packaging that is UN-rated for the material and packing group, then follow closure instructions.
- Apply markings including UN number, Proper Shipping Name, addresses, and special marks such as Limited Quantity or Overpack.
- Apply labels for the primary class and any subsidiary risks.
- Prepare documents such as the Shipper’s Declaration for air or DG manifest for ocean and ground.
- Check segregation and load compatibility if shipping multiple classes.
- Verify placards at the container or trailer level if thresholds are met.
- Pre-advise the carrier with accurate data to avoid day-of refusals.
Frequent Failure Points and How To Prevent Them
- Damaged or wet cartons invalidate the UN packaging performance. Use fresh outers.
- Outdated lithium battery mark on current shipments. Replace old stock and audit monthly.
- Marks covered by wrap or straps. Apply marks last and keep them clear.
- Incorrect quantities on documents compared to what is labeled and marked. Reconcile before pickup.
- Missing Overpack mark on stretch-wrapped pallets containing marked boxes. Add to two sides in high-contrast print.
Quality Check Before Pickup
Use this five-minute check:
- Packaging matches the material and packing group, closures completed per instruction.
- UN number and Proper Shipping Name marked and legible on two sides.
- Required orientation arrows, Limited Quantity or Overpack marks applied if used.
- Primary and subsidiary labels present, clean, and not overlapped.
- Documents prepared with quantities, weights, and descriptions aligned to the package.
- If applicable, trailer or container placarded on all four sides.
How Journey Helps
Your team needs shipments accepted on the first attempt. Journey acts as your hands-on DG partner so you avoid refusals and protect customer timelines.
- Pre-shipment reviews of SDS, UN classifications, and packaging selections.
- Mode-specific checklists for air, ocean, and ground so teams do not miss steps.
- Carrier coordination and pre-advice to prevent last-minute surprises.
- Cross-border guidance for U.S.–Canada movements and drayage at ports and ramps.
- Exception response if something changes mid-route.
Explore related services:
- Customs Brokerage
- International air and ocean, and drayage solutions available through your Journey team.
Important Note
Regulations vary by mode and jurisdiction. Always consult the applicable rule set for your shipment. Journey provides guidance and coordination support to help you ship safely and compliantly.
