UN & DOT Package Certification

The process for obtaining United Nations (UN) and/or U.S. Department of Transportation (DOT) certification on packages containing dangerous goods is described in the following paragraphs.
UN regulations for certification are defined by the “Recommendations on the Transport of Dangerous Goods” AT/SG/AC.10/1/Rev. 12, Part 6. DOT regulations are defined by Title 49 CFR Parts 173 & §178.

The process begins with the Applicant submitting their package to an authorized Package Certification Agent (PCA), such as DDL, along with a detailed description (audit) of the packaging material specifications. These specifications are required before testing can start and are accessible from the manufacturers of the packaging materials. Engineering drawings of the package assembly are also needed. In the absence of these specs, the PCA will perform a detailed audit on all packaging materials. The Applicant is required to submit the total number of complete package assemblies needed by the PCA for performance testing. The quantity varies depending on the type of package and certification requirements.

Example: A 4G-combination package requires eleven complete packages. The packages are prepared as they would be for normal shipping; except that the inner containers are filled a non-hazardous substance - usually water.

The following tests are performed on a 4G-combination package. The Packing Group and product density of the actual filler determines performance levels used for testing.

Cobb Water Absorption Test — this test is performed on the corrugated box in accordance with ISO 535 & 49 CFR §178.516. Samples are conditioned at ambient conditions (73ºF/50% RH) for 24 hours prior to testing, which consists of a 30-minute soak in water. Five samples are prepared for this test.

Drop Test — five complete packages are dropped from the required drop height; a sample is dropped once, in five different orientations for a total of five drops. Primary inner packages (i.e. bottles) made of plastic are conditioned to 0ºF for 24 hours prior to testing. All other inner package materials are conditioned at ambient conditions (73ºF/50% RH) for 24 hours prior to testing. Reference: UN §5.1.6.3 and 49 CFR §178.603.

Stack Test — this test is performed on three complete packages by loading each individual box with a weight equivalent to a 3-meter stack of identical boxes. This test may be performed with or without the primary inner packages (i.e. bottles). The test duration is 24 hours per sample. Samples are conditioned at ambient conditions (73ºF/50% RH) for 24 hours prior to testing. Reference: UN §5.1.6.6 and 49 CFR §178.606.

Vibration Test — this test is performed on three complete packages and requires the operator to determine the acceleration needed to cause the package to leave the surface of the test table. This is accomplished by increasing frequency of the shaker until the package separates enough so that a 1/16-inch shim can slide between the package and the table surface. Once the test level is determined, the test duration is one hour. Samples are conditioned at ambient conditions (73ºF/50% RH) for 24 hours prior to testing. Reference: 49 CFR §178.608.

Optional Tests:

Hydrostatic Pressure Test — this test is performed on three primary inner packages (i.e. bottles) by pressurizing the bottles to the required pressure with water for a specified duration. This test is only required for inner packages that contain liquid and will be
shipped by air. Testing is performed on three samples, including the closures. Reference: UN §5.1.6.5 and 49 CFR §178.605.

ISTA Test — this is a drop and vibration test performed on three complete package designs. A ten-drop sequence and loose load vibration test are performed. This test is only required if UPS will be used to ship your package design containing hazardous materials.

Upon successful completion of these tests the PCA will issue a certificate of compliance, which allows the Applicant to apply the UN markings on the complete package assembly. The marking may look like the one shown at right.

This mark certifies a 4G-type package for Packing Group II products, having a mass not exceeding 15 kg. The “S” denotes it is either a solid product or a combination package. The 01 date is the date of manufacture of the outer package (i.e. shipper or box) or the date of assembly. The +AJ is the PCA identification symbol (AJ is specific to DDL).

The applicant can expedite the certification schedule by providing a detailed list of the packaging materials and specifications along with the required package samples. This information is documented in the final test report issued by the PCA. The Applicant receives one copy of the
final test report while the original remains on file with the PCA. All test reports are treated as confidential information by the PCA.

The preceding summarizes a very complex package certification procedure. Once completed and certification is issued, the package remains in compliance with UN/DOT standards for one to two years, depending on actual package type. Retesting at the end of the certification period is required if the package design remains in use. As a courtesy, DDL will mail out a reminder to retest two months prior to the end of the certification period. However, it remains the Applicant’s responsibility to make sure their package is currently certified while in use.

Our standard turn-around time is seven days. When your schedule demands special handling, we can expedite your job in three days.

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For more information on UN & DOT Package Certification, contact us or call 1.800.229.4235.