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 online training is more comprehensive, has better slides, and is a superior training experience than what I would get from other trainers.

Robert Brenner

District Environmental Manager

The training was impressive. I am not a fan of online training but this was put together very well. I would recommend Lion to others.

Donnie James

Quality Manager

Excellent course. Very interactive. Explanations are great whether you get the questions wrong or right.

Gregory Thompson

Environmental, Health & Safety Regional Manager

I love that the instructor emphasized the thought process behind the regs.

Rebecca Saxena

Corporate Product Stewardship Specialist

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

Excellent job. Made what is very dry material interesting. Thoroughly explained all topics in easy-to-understand terms.

David Hertvik

Vice President

The price was reasonable, the time to complete the course was manageable, and the flexibility the online training allowed made it easy to complete.

Felicia Rutledge

Hazmat Shipping Professional

I tried other environmental training providers, but they were all sub-standard compared to Lion. I will not stray from Lion again!

Sara Sills

Environmental Specialist

My experience with Lion classes has always been good. Lion Technology always covers the EPA requirements I must follow.

Steven Erlandson

Environmental Coordinator

Lion Technology workshops are amazing!! You always learn so much, and the instructors are fantastic.

Dorothy Rurak

Environmental Specialist

Download Our Latest Whitepaper

Your hazmat paperwork is the first thing a DOT inspector will ask for during an inspection. From hazmat training records to special permits, make sure your hazmat documents are in order.

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.