Search

Revised USPS Hazmat Packaging Standards for Mail

Posted on 1/28/2025 by Lion Technology Inc.

New Rules for Hazmat Mailers Take Immediate Effect

Effective January 27, 2025, the US Postal Service has revised its standards for mailing hazmat/dangerous goods to require "rigid" outer packaging of a certain strength for most regulated materials. USPS announced the changes to Publication 52, Hazardous, Restricted, and Perishable Mail, in a Final Rule. 

Other revisions in the Final Rule include:
  • Revising the requirements for mailing lithium batteries.
  • Removing quantity restrictions for nonregulated toxic materials like pesticides and insecticides, provided that the new packaging requirements are followed.
  • Removing the requirement to include a phone number on the lithium battery mark.
The Postal Service cites a concerning increase in hazmat mail incidents between 2020 and 2022 as a key influence for new, more stringent mailability rules. A boom in eCommerce shipping, USPS believes, led to more incidents involving hazardous materials released during transportation and/or removed from the mail system. 

Changes made in 2023, USPS says, already helped lower the incident rate by 20%. 

New Packaging Strength Requirement (All Hazmat)

Moving forward, mailers of hazardous materials must use rigid outer packaging that meets minimum strength requirements based on “edge crush” and “burst test” performance. USPS defines “rigid” to mean:
 
“Unable to bend or be forced out of shape, not flexible. Rigid outer packaging is generally interpreted to mean a fiberboard (cardboard) box or outer packaging of equivalent strength, durability, and rigidity.”

Revised USPS Hazmat Packaging Standards for Mail

Revised Rules for Lithium Batteries by Mail

For shippers of lithium batteries contained-in-equipment by mail, the rule allows the use of padded or poly bags as outer packaging, provided the equipment containing the batteries is placed in a secondary container (i.e., the original manufacturer’s box) that can withstand a 1.2-meter drop test.

Read the USPS Final Rule in the January 27, 2025 Federal Register

Tags: hazmat, hazmat shipping, USPS

Find a Post

Compliance Archives

Lion - Quotes

Lion's course was superior to others I have taken in the past. Very clear in the presentation and the examples helped to explain the content presented.

George Bersik

Hazardous Waste Professional

The instructor took a rather drab set of topics and brought them to life with realistic real-life examples.

Tom Berndt

HSE Coordinator

If I need thorough training or updating, I always use Lion. Lion is always the best in both instruction and materials.

Bryce Parker

EHS Manager

I had a positive experience utilizing this educational program. It was very informative, convenient, and rewarding from a career perspective.

John Gratacos

Logistics Manager

This training broke down the regulations in an easy-to-understand manner and made them less overwhelming. I now feel I have the knowledge to make more informed decisions.

Amanda Oswald

Shipping Professional

I have been to other training companies, but Lion’s material is much better and easier to understand.

Mark Abell

Regional Manager

Much better than my previous class with another company. The Lion instructor made sense, kept me awake and made me laugh!

Marti Severs

Enterprise Safety Manager

The course is well thought out and organized in a way that leads to a clearer understanding of the total training.

David Baily

Hazmat Shipping Professional

The instructor was very dedicated to providing a quality experience. She did her best to make sure students were really comprehending the information.

Stephanie Venn

Inventory Control Specialist

Best course instructor I've ever had. Funny, relatable, engaging; made it interesting and challenged us as the professionals we are.

Amanda Schwartz

Environmental Coordinator

Download Our Latest Whitepaper

In-flight hazmat incidents can be disastrous. This guide gives 5 tips for first-time air shippers to consider before offering dangerous goods for transportation on passenger or cargo aircraft.

Latest Whitepaper

By submitting your phone number, you agree to receive recurring marketing and training text messages. Consent to receive text messages is not required for any purchases. Text STOP at any time to cancel. Message and data rates may apply. View our Terms & Conditions and Privacy Policy.